VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI, 590014

SEMINAR REPORT ON

“COMPOSITE MATERIALS”
Submitted in partial fulfillment of
the requirement for the award of the
degree

Bachelor of Engineering
In

“Mechanical Engineering”
Submitted by

SHIVADARSHAN R HILLI 1MJ19ME057

Under the guidance of

Prof. KIRAN K K
ASSISTANT PROFESSOR
Department of Mechanical Engineering
MVJCE, Bengaluru-560067

Department of Mechanical Engineering,

MVJ College of Engineering Bangalore,
Near ITPB, Channasandra,
Bengaluru – 560067
2022-23

 An Autonomous Institute
Affiliated to Visvesvaraya Technological University, Approved by AICTE, New Delhi
Recognized by UGC under 2(F) & 12(B), Accredited by NBA & NAAC
Near ITPB, Channasandra, Bengaluru – 560067

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
Certified that the project work entitled “COMPOSITE MATERIALS” carried out by
SHIVADARSHAN R HILLI, 1MJ19ME057, a bonafide students of MVJ College of Engineering
in partial fulfilment for the award of Bachelor of Engineering in Mechanical Engineering of the
Visvesvaraya TechnologicalUniversity, Belagavi, during the year 2022-23. It is certified that that
all corrections/suggestions indicated for Internal Assessment have been incorporated in the report
deposited in the departmental library. The seminar report has been approved as it satisfies the
academic requirements in respect of TECHNICAL SEMINAR – 19MES83 prescribed for the
said degree.

Signature of the Guide Signature of the HOD

Prof. Kiran K K Dr. Santhosh N

Examiners:
Name of the examiners Signature with date

1. …………………………… ……………………………

2. …………………………… ……………………………

 DECLARATION

We, hereby declare that TECHNICAL SEMINAR – 19MES83 entitled “COMPOSITE

MATERIALS” has been independently carried out by me under the guidance of Kiran K
K, Assistant Professor and Shiva Kumar H D Assistant Professor, Department of
Mechanical Engineering, MVJ College of Engineering, Bangalore, in partial fulfillment of
the requirements of the degree of B.E in Mechanical Engineering of Visvesvaraya
Technological University, Belagavi.

We, further declare that we have not submitted this report either in part or in full to any other
university for the award of any degree

Regards

Name-SHIVADARSHAN R HILLI

USN- 1MJ19ME057

Place: MVJCE, Bengaluru

Date:

 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany a successful completion of any task
would be incomplete without the mention of people who made it possible. So, with gratitude
we acknowledge all those who has guided and encouraged us as beacon of light and crowned
our effort with success.
We are thankful to the Management of MVJ College of Engineering Bangalore for
their continuous support and encouragement for carrying out the TECHNICAL SEMINAR
– 19MES84.
We are thankful to our Dr. P. Mahabaleswarappa, Principal, MVJCE, Bengaluru,
for being a constant inspiration and providing all the facilities that was needed throughout
the TECHNICAL SEMINAR – 19MES84.

We like to express our gratitude to our Dr. M. Brindha, Vice Principal, MVJCE,
Bengaluru, for constant encouragement throughout the course.
We also like to express our sincere gratitude to our Dr. M A Lourdu Antony Raj,
Registrar and Controller for Examinations, MVJCE, Bengaluru, for persistent guidance.
We are thankful to our Dr. Santhosh N, Professor and Head, Department of
Mechanical Engineering, MVJCE, Bengaluru, for being a constant support and providing all
the facilities that was needed throughout the Technical Seminar.
We consider it as a privilege and honor to express our sincere gratitude to our guides
Krishna Prasad R, Assistant Professor and Shiva Kumar H D Assistant Professor, Department
of Mechanical Engineering, MVJCE, for his encouragement that has been a constant source
of motivation to us for successful completion of our Technical Seminar.
We are in debt to the support of all the teaching and non-teaching members of
Department of Mechanical Engineering, for their kind help and co-operation, throughout our
graduation. Their constant support and love have made this journey a memorable.
Finally, we wish to thank our parents for their love and encouragement, without whom
we would never have enjoyed so many opportunities.

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ABSTRACT

Composite materials are a unique class of materials that offer

numerous benefits over traditional materials such as metals and
ceramics. They are made by combining two or more materials, each
with different properties, to create a new material with enhanced
performance characteristics.
Composite materials are widely used in industries such as aerospace,
automotive, marine, and construction due to their high strength-to-
weight ratio, corrosion resistance, and durability.
This abstract provides an overview of composite materials, including
their history, types, advantages, and disadvantages. Additionally, the
different manufacturing processes involved in the production of
composite materials, such as compression molding and filament
winding, are discussed. The potential environmental impact of
composite materials is also highlighted, along with the efforts being
made to improve their sustainability.
Overall, composite materials are a promising class of materials that
offer a wide range of benefits and applications, and ongoing research
and development are expected to drive further improvements and
innovations in this field.

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CONTENT

Page
No.
INTRODUCTION 3

HISTORY 4

ADVANTAGES 5

DISADVANTAGES 7

MATERIALS USED IN COMPOSITES 8

DIFFERENCE BETWEEN THERMOSETTING AND 10

THERMOPLASTIC
COMPARISON TABLE OF VARIOUS COMPOSITE 11
MATERIALS
MANUFACTURING COMPOSITE MATERIALS 12

COMPRESSION MOULDING 13

FILAMENT WINDING 17

CONCLUSION 21

REFERENCES 22

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INTRODUCTION

Composite materials are materials composed of two or more distinct

materials that, when combined, exhibit properties that are different from
those of the individual components. The resulting material is designed to
have superior strength, durability, and other properties compared to
traditional materials.

Composite materials are commonly used in a variety of applications,

such as aerospace, automotive, construction, marine, and sports
equipment. They are typically made up of a reinforcing material, such as
fibreglass or carbon fibre, which is embedded in a matrix material, such
as epoxy or polyester resin.

The reinforcing material provides the composite with its strength and
stiffness, while the matrix material holds the reinforcing material in
place and transfers loads between the reinforcing fibres. Other types of
composites can include metal-matrix composites, ceramic-matrix
composites, and polymer-matrix composites.

Composite materials can be tailored to meet specific requirements, such

as high strength, low weight, or resistance to environmental factors such
as heat, moisture, and chemicals. They offer a number of advantages
over traditional materials, including improved performance, reduced
weight, increased durability, and lower maintenance costs. However,
composite materials can be more expensive than traditional materials,
and they require specialised manufacturing processes and techniques.

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HISTORY

The history of composite materials dates back to ancient times when

humans first used natural materials like mud and straw to build
structures. However, the development of modern composite materials
began in the early 20th century with the discovery of synthetic
polymers and the use of fibers to reinforce materials.
Here are some key milestones in the history of composite materials:

- 1907: Leo Baekeland invented the first synthetic plastic, Bakelite,

which was used in a variety of applications, including electrical
insulation.

- 1930s: Glass fiber was developed as a reinforcement material for

plastics, leading to the creation of fiberglass.

- 1940s: During World War II, composite materials were used

extensively in military applications, such as aircraft components and
boats.

- 1950s-1960s: The development of high-strength fibers, such as

carbon fiber and aramid fiber, paved the way for the creation of high-
performance composites.

- 1960s-1970s: Composite materials were used in the aerospace

industry, with the Boeing 747 and other aircraft incorporating
composites into their designs.

- 1980s-1990s: Advances in manufacturing processes, such as resin

transfer moulding and automated fibre placement, made it easier and
more cost-effective to produce composite parts.
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- 2000s-present: Composite materials continue to be used in a wide

range of applications, from sports equipment and medical devices to
wind turbines and automotive components. New materials and
manufacturing processes are constantly being developed to improve
the performance and versatility of composites.

Today, composite materials are an essential part of modern

manufacturing, offering a range of unique properties, including high
strength, stiffness, and durability, as well as lightweight and
corrosion-resistant properties.

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ADVANTAGES

1. High strength-to-weight ratio: Composite materials are much

stronger than many traditional materials like steel or aluminium,
yet much lighter, allowing for lightweight and strong structures.

2. Design flexibility: Composite materials can be designed to

have specific properties and can be folded into complex shapes,
making them ideal for creating custom parts and structures.

3. Corrosion resistance: Unlike metals, composite materials are

not susceptible to corrosion, making them ideal for use in harsh
environments.

4. Excellent electrical properties: Some composite materials are

excellent electrical insulators, making them ideal for use in
electrical and electronic applications.

5. Low thermal expansion: Composite materials have a low

coefficient of thermal expansion, meaning they are less likely to
warp or distort when exposed to high temperatures.

6. Reduced maintenance requirements: Composite materials

require less maintenance than traditional materials, such as steel
or wood, which can be prone to rust, rot, and other types of
damage.

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DISADVANTAGES

1. High cost: Composite materials are often more expensive than

traditional materials, such as steel or aluminum, due to the high
cost of the raw materials and the manufacturing process.

2. Manufacturing complexity: Composite materials require

specialized equipment and skilled labor to manufacture, which
can add to the overall cost.

3. Environmental concerns: Some composite materials are not

biodegradable and can be difficult to recycle, leading to
environmental concerns.

4. Susceptibility to impact damage: Composite materials can be

vulnerable to impact damage, which can cause cracking and
delamination.

5. Susceptibility to UV damage: Some composite materials can

degrade when exposed to UV radiation, leading to discoloration
and loss of mechanical properties.

6. Flammability: Some composite materials are flammable and

can be difficult to extinguish once they catch fire.

7. Moisture absorption: Some types of composite materials can

absorb moisture, which can lead to swelling, distortion, and loss
of mechanical properties.

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MATERIALS USED IN COMPOSITES

Composite materials are typically composed of two or more

materials, with one of them being a reinforcement material and
the other being a matrix material. Some common reinforcement
materials used in composites include:
1. Fibres - such as carbon fibre, glass fibre, and aramid fibre.
2. Particulates - such as metal powders and ceramic particles.
3. Woven fabrics - such as carbon or glass cloth.
4. Matting - a non-woven fabric made of fibres or chopped
strands.

Glass Fibre Metal Powder

Women Fabrics Matting

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The matrix material serves to bind the reinforcement material

together and transfer loads between the fibres or particles. Some
common matrix materials used in composites include:

1. Thermosetting resins - such as epoxy, polyester, and vinyl

ester
2. Thermoplastic resins - such as nylon, polycarbonate, and
polyethylene
3. Ceramic matrices - such as silicon carbide or alumina
4. Metal matrices - such as aluminium or magnesium

Epoxide Polycarbonate

Magnesium Alumina Matrices

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MATERIALS USED IN COMPOSITES

FIBRES MATRIX FILLERS
Natural Fibres Polyethylene Nanoparticles
Ex:Hemp Ex: Silica
Ceramic Fibres Epoxy Conductive Particles
Ex: Alumina Ex: Graphite
Aramid Fibres Nylon Metal Powders
Ex: Kevlar
TABLE:1

DIFFERENCE BETWEEN THERMOSETTING AND

THERMOPLASTIC 


Thermosetting Thermoplastic
Property Materials Materials
Behavior when Harden irreversibly Soften and melt
heated
Chemical reaction Undergo cross- No cross-linking
linking
Ability to reshape Cannot be Can be reshaped
reshaped multiple times
Curing process Requires heat and Does not require
pressure heat and pressure
Properties after Become infusible Remain fusible and
curing and insoluble soluble
Examples of Epoxy, phenolic, Polyethylene,
materials and polyester polycarbonate,
resins nylon, and PVC
TABLE:2
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COMPARISON TABLE OF VARIOUS

COMPOSITE MATERIALS

Ther
Strength Corro
Fatigue mal
Composit -to- Stiff sion
Resista Cond
e Material Weight ness Resist
nce uctivit
Ratio ance
y
Carbon
Fiber
Very Very Very Excell
Reinforced Low
High High Good ent
Plastic
(CFRP)
Glass Fiber
Reinforced Excell
High High Good Low
Plastic ent
(GFRP)
Aramid
Fiber
Excell
Reinforced High High Good Low
ent
Plastic
(AFRP)
Metal
Matrix Excellen
High High Good High
Composite t
s (MMC)
Ceramic
Matrix Very Excellen Very
High Good
Composite High t Low
s (CMC)
TABLE:3

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MANUFACTURING COMPOSITE MATERIALS

METHODS :

Here is a list of some common methods for making composite

materials:

1.Compression moulding: In this method, fiber reinforcement and

resin are placed in a mold, which is then compressed under heat and
pressure to form the composite part.

2.Filament winding: In this method, continuous fibers are wound

around a rotating mandrel to create a seamless tube or other cylindrical
shape.

3. Spray-up: Similar to hand layup, spray-up involves spraying

chopped fibers and resin onto a mold or tool using a spray gun.

4. Pultrusion: This continuous process involves pulling fiber

reinforcement through a bath of resin, then through a die to shape the
composite into a constant cross-section.

5. Resin transfer molding (RTM): This closed-mold process involves

injecting resin into a mold cavity containing pre-placed fiber
reinforcement.

6. Vacuum bagging: In this method, fiber reinforcement and resin are

placed in a mold and then covered with a vacuum bag, which is sealed
and evacuated to remove air and consolidate the laminate.

7. Prepreg layup: Prepregs are pre-impregnated fibers that are ready to

use in composite layup. Prepregs can be manually placed on a tool or
mold and then heated to cure the resin.
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8. Injection moulding: This process involves injecting molten plastic

or other materials into a mold to create a solid part. Reinforcing fibers
can also be added to the molten material to create composite parts.

9. Hand layup: In this process, layers of fiber reinforcement and resin

are manually placed on a mold or tool, and then compressed to remove
air bubbles and excess resin.

These are just a few of the many methods used for making composite
materials. The choice of method depends on factors such as the size,
shape, and complexity of the part, as well as the desired mechanical
properties and cost of the final product.

COMPRESSION MOULDING

Compression molding is a manufacturing process used to produce

composite parts by compressing preheated, thermoset materials in a
mold cavity.

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Here are the details of the compression molding process:

1. Preheating: The first step in compression molding is to preheat the

composite material in a heated mold to a specific temperature. The
temperature depends on the type of composite material being used and
is typically in the range of 100-200°C.

2. Loading: Once the composite material is preheated, it is placed into

the mold cavity. The amount of material used is carefully controlled to
ensure that the mold cavity is completely filled.

3. Compression: The mold is then closed, and a hydraulic press applies

pressure to the material in the mold cavity. The pressure is typically in
the range of 1000-5000 psi and is maintained for a specific time period
to allow the material to cure and solidify.

4. Cooling: After the material has been compressed and cured, the mold
is cooled to allow the material to harden and take on the desired shape.

5. Ejection: Finally, the mold is opened, and the finished part is ejected
from the mold. Any excess material is trimmed, and the part is inspected
to ensure that it meets the required specifications.

Compression molding is a popular manufacturing process used for

producing a wide range of composite parts, from small components to
large panels. It is especially useful for producing complex shapes and
parts with high strength and stiffness requirements, such as aircraft parts
and automotive components.

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Pic: Compression Moulding

Pic : Compression Moulding Box

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Advantages and disadvantages of Compression

moulding

Advantages of Compression Disadvantages of

Molding Compression Molding
Ability to produce large, complex High start-up costs due to
parts expensive molds and machinery
High production rates and Limited flexibility for changes in
efficiency design or material
Ability to use a wide range of Longer cycle times compared to
materials, including other molding techniques
thermosetting and thermoplastic
resins
Low scrap rate and material Limited control over part
waste thickness and surface finish
Ability to incorporate inserts or Potential for voids or air pockets
reinforcements into parts in the finished part
Consistent, high-quality parts Limited part size due to mold
size constraints

Table:3

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FILAMENT MOULDING

Filament winding is a manufacturing process used to produce

cylindrical composite structures, such as pipes, tanks, and pressure
vessels. Here are the details of the filament winding process:

1. Mandrel preparation: The first step in filament winding is to prepare

a mandrel, which is a cylindrical form around which the composite
material will be wound. The mandrel is typically made of steel or
aluminum and is coated with a release agent to prevent the composite
material from sticking.

2. Material preparation: The composite material used in filament

winding is typically a fiber reinforced polymer (FRP), such as
fiberglass or carbon fiber, impregnated with a thermosetting resin. The
material is prepared by passing the fibers through a resin bath or
impregnation system to coat them with resin.

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3. Filament winding: The composite material is then wound around the

mandrel using a winding machine. The machine consists of a rotating
mandrel and a carriage that moves back and forth along the length of
the mandrel, laying down the composite material in a precise pattern.

4. Curing: After the composite material has been wound onto the
mandrel, it is cured to solidify the resin and create a rigid structure.
Curing is typically achieved through the application of heat, either in
an oven or through the use of infrared lamps.

5. Demolding: Once the composite structure has been cured, the

mandrel is removed from the inside of the structure. The structure is
then inspected and any excess material is trimmed off.

Filament winding is a versatile manufacturing process that can be used

to produce composite structures of varying sizes and shapes. It is
commonly used in the aerospace, automotive, and construction
industries, as well as in the production of sporting goods and other
consumer products. The process offers several advantages over other
composite manufacturing methods, including high strength-to-weight
ratios, precise control over fiber orientation, and the ability to produce
complex geometries.

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Pic : Filament Moulding setup

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Advantages And Disadvantages Of Filament Winding

Advantages of Filament Disadvantages of Filament

Winding Winding
Ability to produce high-strength, High start-up costs due to
lightweight parts expensive equipment and
tooling
Ability to manufacture complex Limited flexibility for changes in
shapes and contours design or material
Low material waste and high Limited control over part
material utilization thickness and surface finish
Ability to incorporate continuous Longer cycle times compared to
fibers for enhanced strength and other molding techniques
stiffness
Consistent, repeatable part Limited part size due to mandrel
quality size constraints
High production rates and Difficulty in producing parts with
efficiency sharp corners or angles

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CONCLUSION
In conclusion, composite materials have emerged as a vital class of
engineering materials, offering many advantages over traditional
materials such as steel and aluminium. They have a wide range of
applications in various industries, including aerospace, automotive,
construction, and sports equipment.

The ability to tailor the properties of composites by combining

different materials and production techniques has led to significant
improvements in strength, stiffness, weight, and durability, making
them ideal for use in high-performance applications.

While composite materials have many advantages, they also have

some limitations, including higher costs, environmental concerns, and
susceptibility to certain types of damage. However, ongoing research
and development in the field of composite materials are addressing
these challenges, leading to the development of new and improved
materials that offer even greater performance and durability.

Overall, composite materials have revolutionised the way engineers

approach design and manufacturing, and their continued development
is sure to drive progress in a wide range of industries in the years to
come.

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REFERENCES
1. Jones, R. M. (1999). Mechanics of composite materials. CRC press.

2. Mallick, P. K. (2007). Fiber-reinforced composites: materials,

manufacturing, and design. CRC press.

3. Gibson, R. F. (2012). Principles of composite material mechanics.

CRC press.

4. Hull, D., & Clyne, T. W. (1996). An introduction to composite

materials (2nd ed.). Cambridge University Press.

5. Agarwal, B. D., & Broutman, L. J. (2009). Analysis and performance

of fiber composites (3rd ed.). John Wiley & Sons.

6. Barbero, E. J. (2010). Introduction to composite materials design (2nd

ed.). CRC press.

7. Ishai, O., & Karni, R. (2016). Mechanics of advanced materials:

Analysis of properties and performance. Elsevier.

8. Fong, Y. C., & Hsieh, T. E. (2019). Composite materials: properties,

manufacturing, and applications. Woodhead Publishing.
9. Kuczmarski, M. A., & Hitchcock, R. W. (Eds.). (2018). Composite
materials handbook-17: volume 1. CRC press.

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