KH6064MAA Materials Analysis and Advanced Manufacturing

7. Theory and Technology of Composite Materials

Dr. Ahmed Shaker

Assistant Professor of Mechanical Engineering

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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

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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.

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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.

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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)

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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.

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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.

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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.

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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

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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

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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

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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

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Types of composite materials
I- Classification based on the matrix type

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II- Classification based on the reinforcement type

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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

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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.

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Influence of fiber length

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Influence of fiber orientation and concentration

Parallel
alignment
Orientation
Random
alignment

Better overall composite properties are realized when the fiber

distribution is uniform.

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Stress-Strain relationship for longitudinal loaded material
(in the direction of fiber alignment)

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 Elastic behavior
(longitudinal loading ) 𝐹𝑐 = 𝐹𝑚 + 𝐹𝑓
𝜎𝑐 𝐴𝑐 = 𝜎𝑚 𝐴𝑚 + 𝜎𝑓 𝐴𝑓

If the composite, matrix and fiber 𝐴𝑚 𝐴𝑓

phase lengths are all equal 𝜎𝑐 = 𝜎𝑚 + 𝜎𝑓
𝐴𝑐 𝐴𝑐
𝜎𝑐 = 𝜎𝑚 𝑉𝑚 + 𝜎𝑓 𝑉𝑓
𝑭𝒄 is the total load sustained by the composite
𝜀𝑐 = 𝜀𝑚 = 𝜀𝑓
𝑭𝒎 is the carried load by matrix
𝑭𝒇 is the carried load by fiber 𝜎𝑐 𝜎𝑚 𝜎𝑓
= 𝑉𝑚 + 𝑉𝑓
𝑬𝒄𝒍 is the modulus of elasticity of continuous and 𝜀𝑐 𝜀𝑚 𝜀𝑓
aligned fibrous composite 𝐸𝑐𝑙 = 𝐸𝑚 𝑉𝑚 + 𝐸𝑓 𝑉𝑓

𝐸𝑐𝑙 = 𝐸𝑚 1 − 𝑉𝑓 + 𝐸𝑓 𝑉𝑓
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Assignment
𝐹𝑓 𝐸𝑓 𝑉𝑓
Prove that =
𝐹𝑚 𝐸𝑚 𝑉𝑚

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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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Thank you!