COMPOSITES

i. What are Composites? PART - A

ii. Why we need Composites?
iii. What are the Components present in a
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iv. Matrix – Types
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v. Reinforcements – Types PART - A
vi. MMC - Properties & Applications PART - B
vii. PART - B
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MC -
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ix. Hybrid Composites
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x. PART - B
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 What are Composites?
• Definition:
A composite is a material which is produced
from two or more materials, having
dissimilar chemical or physical properties and
are merged to create a new material with
properties superior than individual elements.
• Within the finished structure, the individual
elements remain separate and distinct.
 Why we Need Composites?
Our modern life style , industrial revolution and our modern
technologies all require materials with unusual combinations
of properties that can not be met by conventional metals,
alloys, ceramics and polymeric materials.
This is especially true for aerospace, underwater and
transportation applications.
For example, aircraft engineers are increasingly searching for
structural materials that have low densities, are strong, stiff,
and abrasion and impact resistant, and are not easily
corroded. This is a rather difficult combination of
characteristics.
This is why, we need to engineer new materials, called
composites, by combining various existing ones
• Composites offer many benefits; the key among
them are
• light weight, and strength
• High specific strength (Strength to weight ratio)
• High tensile strength(amount of stress a material
can handle before it breaks, cracks, becomes
deformed) (steel -400 to 690 MPa, while CRPC from
1,200 to 2,410 Mpa)
• corrosion resistance,
• design flexibility,
• durability,
Composites have permeated our everyday lives such
as products that are used in constructions, medical
applications, oil and gas, transportation, sports,
aerospace, and many more
 What are the components of a
composite?
A composite consists of two components:
(i) the matrix as the continuous phase;
(ii) the reinforcements as the discontinuous or
dispersed phase,
By carefully choosing the matrix, the
reinforcement, and the manufacturing
process, we can make several products to
meet specific requirements
REINFORCED CONCRETE
EGYPTIAN HOUSE
MANGOLIAN’S BOW
WOOD
Wood is a natural composite material that is
composed of cellulose fibres, lignin
matrix, and hemicellulose.
Cellulose fibres are actually weak substance,
and lignin and hemicellulose are even weaker.
The long cellulose fibres held together by
lignin and hemicellulose.
Together, they form much stronger wood,
even they are weak as an individual.
 MATRIX MATERIALS
The matrix is basically a homogeneous and monolithic
(huge mass) material in which a fibre is embedded.
It is completely continuous. The matrix binds
the fibres together and distributes the load.
It also provides ductility and separates the fibres
and prevents propagation of cracks from one fibre
to the next.
It is also essential that there is no chemical reaction
between the matrix material and fibres and that the
matrix material does not cause damage to the fibres.
 TYPES OF MATRIX MATERIALS
Matrix materials are of 3 types
1. Metals – Al, Mg, Ti Cu, Alloys
2. Polymers – Thermoplastics or Thermosets
3. Ceramics – C, SiC, Al2O3 or Mullite Al2O3-SiO2
Accordingly , we have
1. Metal Matrix Composites,
2. Polymer Matrix Composites and
3. Ceramic Matrix Composites
In reality, the majority of matrix materials that
exist on the composites market are polymer.
 REINFORCEMENTS
Reinforcements are materials used to increase the
mechanical properties of a composite. It Provides
superior levels of strength and stiffness to the
composite.
These Composite reinforcements can be in various
forms such as
fibres,
Flakes /whiskers, or
particles.

Each of these has its own properties and therefore,

each has its own area of applications.
Composites based on Reinforcement
Among the various reinforcing agents,
fibres are the most commonly used in
composite applications
Various types of fibres have been utilised
to reinforce polymer matrix composites.
The most common are
carbon fibres (AS4, IM7, etc.),
glass fibre (E-glass, S-glass,etc.),
® ®
aramid fibres (Kevlar and Twaron ),(aromatic
polyamide) and boron fibres.
Most common reinforcing materials used
are Glass fibre & carbon fibre,
CARBON FIBRE

Carbon fibres (alternatively graphite fiber ) are fibres about 5 to 10

micrometers in diameter and composed mostly of carbon atoms. Carbon
fibres have several advantages including
high stiffness,

high tensile strength,

high strength to weight ratio,

high chemical resistance,

high temperature tolerance and low thermal expansion.

These properties have made carbon fibre very popular in aerospace, civil
engineering, military, and motorsports, along with other competition
sports.

However, they are relatively expensive when compared with similar

fibers, such as glass fibre, basalt fibres, or plastic fibers.

Several thousand carbon fibers are bundled together to form a tow.

Carbon fibers are usually combined with other materials to form
a composite. When combined with a plastic resin it forms carbon-fiber-
reinforced polymer . Carbon fibers are also composited with other
materials, such as graphite, to form reinforced carbon-
carbon composites, which have a very high heat tolerance.

carbon fibre tow

GLASS FIBRE
Glass fibres are the oldest and the most common used
reinforcement material. Glass fibre weighs more than the
second most common reinforcement, carbon fibre, and is
not as stiff, but is more impact-resistant and has a greater
elongation-to-break (that is, it elongates to a greater
degree before it breaks).
Glass fibres are used primarily to reinforce polymers. The
leading types of glass fibers are E-glass, high-strength (HS)-
glass, and corrosion resistant (CR)-glass.
 E-glass fibers are the most widely used of all fibrous
reinforcements. Electrical or E-glass, is an excellent
electrical insulator, is particularly well-suited to
applications in which radio-signal transparency is desired,
such as aircraft radomes, antennae and printed circuit .
It is also the most economical glass fibre for composites,

When greater strength is desired, high-strength glass can

be used.
Corrosion-resistant glass, known as C-glass or E-CR glass,
stands up better to an acid solution than does E-glass.
GLASS STRAND
ARAMID FIBRE
Aramid fibers, formed from aromatic polyamide, provide excellent
impact resistance and good elongation (higher than carbon, but less
than glass), high heat resistance and posses high melting point.

Used in bulletproof vests and other armor and ballistic applications.

Aramid fiber has been in demand in part due to the need for
personnel protection and armor in law-enforcement and military
markets.

Aramid’s properties also make the fiber an excellent choice for

helicopter rotor blades, marine vessel hulls and sporting goods where
impact resistance is desired .
• Generally the properties and behaviour of
all composites depend on the following:
• 1. Concentration of reinforcing materials
• 2.Their size
• 3.Their shape
• 4. Their spatial distribution & finally
• 5. Their orientation
METAL MATRIX
COMPOSITES
METAL MATRIX COMPOSITES
• Metal matrix composites (MMCs) are a type
of composite in which a metal fused with
another substance.
• The base material is a metal matrix, while
the reinforcing material appears as fibres or
particulates .
• The aim of manufacturing such a material is to
enhance the existing properties of the metal
matrix, by adding reinforcement materials.
Some examples of most commonly used
metal matrix configurations are:
1. Aluminum-based composites; ( AlMgSi, AlMg,
AlCuSiMn, AlZnMgCu, AlCu, AlSiCuMg)
2. Magnesium-based composites
3. Titanium-based composites
4. Copper-based composites
5. Alloy-based composites
Aluminum is the most commonly used
matrix material in MMCs.
Some of the most common reinforcing materials
used are carbon fibre, silicon carbide,
alumina, and boron.
 Properties of Metal Matrix
Composites
1. High Strength
One of the most common features of metal matrix composite
materials is increased strength and stiffness. Its high strength-
to-weight ratio makes the material useful in a wide variety of
applications.
Most metal matrix composites have high mechanical strength.
2. High Heat Resistance
Metal matrix composites work best in industries with a high risk
of creep fatigue or sudden temperature changes. (welding ).
Other Unique Properties
low density,
Fire resistance
Do not absorb moisture
Radiation resistance
Increased resistance to wear and tear
 Examples of Metal Matrix
Composites
Most of the composites available in the market are usually classified under
the following:
Aluminium MMC
These composites make use of aluminium as the base metal matrix. Examples
include aluminium-graphite composite, and aluminium-beryllium composites
Magnesium MMC
Magnesium is another excellent matrix material for composites. Some products in this
category include magnesium -silicon carbide (Mg-SiC), magnesium-
aluminium oxide (Mg-Al2O3) and magnesium-titanium carbide (Mg-TiC).
Titanium MMC
Pure titanium is already a strong material in itself, but its composite form
may enhance its superior strength.
Other MMCs
Other less common but highly useful matrix base materials used for
composites include copper, cobalt, nickel, or a combination of metals.
Applications of Metal Matrix Composites
1.Aerospace and Aircraft Industry
Metal matrix composites work well as components in

transmission systems, gearboxes, engine parts

and accessories, and other internal elements.
2.Sports

The superior strength-to-weight ratio of most metal

matrix composites makes the material suitable for
 tennis rackets, bicycle frames, and other sports
that involve speed and strength.
3.Automotive Applications
Car and motor racing make use of metal matrix

composites for engine and vehicle body parts due

to the lightweight nature of the material.
Diesel engine pistons, cylinder liners, brake drums,
and brake rotors , connecting rods, piston pins,
and drive shafts.