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Comp. 1

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ahmedkahttouni
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Zagazig University - Faculty of Engineering

Elective course 1
Theory and Technology of Composite
Materials
Subject code: DPE 311
3rd Year Mechanical Power Engineering

Instructor
Dr. Ahmed Shaker
Assistant Professor – Mechanical Design and Production
Engineering Department
Contents
1. Introduction
2. Particle reinforced composites
3. Fiber reinforced composites
4. Polymer matrix composites
5. Metal matrix composites
6. Ceramic matrix composites
7. Hybrid composites
8. Processing of fiber reinforced composites
9. Structural composites
Definition

 Composite materials are formed by the combination of two or

more materials such that resulting properties are superior to


those of its constituents

 The design of modern structures often requires material

capabilities, which are difficult to obtain with traditional


materials.
Advantages of composite materials
1) Low-density and light weight
2) High-strength and stiffness
3) High-damping
4) Thermal-shock resistance
5) High fatigue behavior
6) High corrosion resistance
7) Fire resistance
8) Ability to form complex shapes
9) Very tolerant to environmental effects such as UV damage,
moisture, chemical attack and temperature extremes.
Disadvantages of composite materials
1) Properties are generally anisotropic (they differ depending
on direction)
2) Complex repair process
3) Generally expensive
4) Manufacturing methods often slow
5) One of the most common types of layered composite
failure is delamination (debonding of one layer from
another)
Applications of composite materials

Aerospace as planes of Boeing


777 (and in 767, 787 airplanes)

Fiberglass is a popular material


for boats and marine sector.
This composite material is
lightweight and is suited for
every weather condition.
The main reason for the shift
towards composite trucks is the
lighter load, the resulting fuel
savings and the composite trucks
work well in all climates.

Fiberglass reinforced polymer


(GFRP) plays an important role in
manufacturing trains, busses,
metros, and trams. Its lightness and
rigidity make it the perfect material
for public transportation. They are
characterized by their fire safety.
Glass Fiber with suitable matrix is
used in water pipes for their high
strength and corrosion resistance.
(tubes of 1.5m diameter, 1km long
tube).

Wind energy is a renewable energy


resource, composites are used in
manufacturing of wind mill blades for
their high stiffness, low density, and
good fatigue performance.
Components in Composite Materials
Most of composite materials consist of two phases:

1. The primary phase in which the other phase is embedded:


Matrix

Such as metal, ceramic or polymer.


It transfer load to reinforcement
2. The secondary phase or imbedded phase that strengthens the
composite: Reinforcement

 In the form of fibers, particles, flakes or various other


geometries.
 Provide an improvement in tensile strength, stiffness and
impact resistance to the material.

Shapes of embedded phases in composite materials: (a) fiber, (b) particle,


and (c) flake
There are geometrical and spatial characteristics of the dispersed
phase that may influence the properties of composites
a) Concentration
b) Size
c) Shape
d) Distribution
e) Orientation
The Interface and Interphase

 Interface is between the primary and secondary phases in a


composite material
 Interphase a third ingredient (component) must be added to
achieve bonding of primary and secondary phases can be
thought of as an adhesive
Types of composite materials
I- Classification based on the matrix type
II- Classification based on the reinforcement type
Particle reinforced composites
Dispersion-
Large particle
strengthened
The distinction between these two types of materials is based on
reinforcement or strengthening mechanism.

• Particle-matrix interactions • Particles are much smaller


cannot be treated on the (10-100 nm)
atomic or molecular level • Particle-matrix interactions
• Continuum mechanics is used are on the atomic or
• The particulate phase is molecular level
harder and stiffer than the
matrix
Fiber-reinforced composites
The mechanical characteristics of fiber-reinforced composite
depend not only on the properties of the fiber, but also on the
degree to which an applied load is transmitted to the fibers by the
matrix.
∗
𝜎𝑓 𝑑
𝑙𝑐 =
2𝜏𝑐

Under an applied stress, the fiber-matrix bond ceases at the fiber


ends, yielding a matrix deformation pattern.
Influence of fiber length
Influence of fiber orientation and concentration

Parallel
alignment
Orientation
Random
alignment

Better overall composite properties are realized


when the fiber distribution is uniform.
Stress-Strain relationship for longitudinal loaded material
(in the direction of fiber alignment)
Elastic behavior 𝐹𝑐 = 𝐹𝑚 + 𝐹𝑓
(longitudinal loading )
𝜎𝑐 𝐴𝑐 = 𝜎𝑚 𝐴𝑚 + 𝜎𝑓 𝐴𝑓
If the composite, matrix 𝐴𝑓
𝐴𝑚
and fiber phase lengths are 𝜎𝑐 = 𝜎𝑚 + 𝜎𝑓
all equal 𝐴𝑐 𝐴𝑐
𝜎𝑐 = 𝜎𝑚 𝑉𝑚 + 𝜎𝑓 𝑉𝑓
𝑭𝒄 is the total load sustained by the
𝜀𝑐 = 𝜀𝑚 = 𝜀𝑓
composite
𝑭𝒎 is the carried load by matrix 𝜎𝑐 𝜎𝑚 𝜎𝑓
= 𝑉𝑚 + 𝑉𝑓
𝑭𝒇 is the carried load by fiber 𝜀𝑐 𝜀𝑚 𝜀𝑓
𝑬𝒄𝒍 is the modulus of elasticity of 𝐸𝑐𝑙 = 𝐸𝑚 𝑉𝑚 + 𝐸𝑓 𝑉𝑓
continuous and aligned fibrous
𝐸𝑐𝑙 = 𝐸𝑚 1 − 𝑉𝑓 + 𝐸𝑓 𝑉𝑓
composite
Assignment
𝐹𝑓 𝐸𝑓 𝑉𝑓
Prove that =
𝐹𝑚 𝐸𝑚 𝑉𝑚
Elastic Behavior – Transverse Loading

𝜎𝑐 = 𝜎𝑚 = 𝜎𝑓 = 𝜎 Isostress state
𝜀𝑐 = 𝜀𝑚 𝑉𝑚 + 𝜀𝑓 𝑉𝑓

𝜎 𝜎 𝜎
= 𝑉𝑚 + 𝑉𝑓
𝐸𝑐𝑡 𝐸𝑚 𝐸𝑓

1 𝑉𝑚 𝑉𝑓
= +
𝐸𝑐𝑡 𝐸𝑚 𝐸𝑓

𝐸𝑚 𝐸𝑓 𝐸𝑚 𝐸𝑓
𝐸𝑐𝑡 = =
𝑉𝑚 𝐸𝑓 + 𝑉𝑓 𝐸𝑚 1 − 𝑉𝑓 𝐸𝑓 + 𝑉𝑓 𝐸𝑚
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