COMPOSITE TECHNOLOGY

MDP 453

An Introduction

A material system composed of a combination of two or

more constituents that differ in form or material
composition and are essentially insoluble in each other

MDP 453 Composite Technology

 We are going to address…
 What are composite materials?
 What are the types and classes of composites?
 Why do we use composites instead of metals,
polymers and ceramics?
 What are some common applications of composites?

MDP 453 Composite Technology

 Definition of a Composite
 A composite is a class of materials that
combines different materials with the
objective of getting more desirable
combinations of properties.
 The combination is in such a way that
each material remains separate and
distinct on a macroscopic level within
the finished structure.

Tail of an RC
Plywood helicopter
MDP 453 Composite Technology
 Why use Composite Materials?
 Allows a material performance unattainable by the
individual constituents.
 can overcome the limit of properties of current
monolithic materials
 offers a great advantage of flexible design.
 possible to tailor the properties of composite
materials by selecting, shaping and distributing of raw
materials
 can develop or design new materials with desired or
improved properties

MDP 453 Composite Technology

 Composites vs. Other

MDP 453 Composite Technology

 The Science of Composites
 Extremely broad area
– deals with almost all kinds of materials based on metals,
ceramics and polymers
– Remains a complicated unsolved area compared to
monolithic materials
– related with the most of emerging technologies (aerospace
technology, biotechnology,micro-electronic technology …)
 Rapidly developing new area
– Most technologies were developed within about recent 20
years
– One of the most hot research area in materials science
– About 1/3 of published papers in international journals on
materials science are related with composite materials

MDP 453 Composite Technology

 Example for composite development

MDP 453 Composite Technology

 Classification of Materials
 Metallic materials: pure metals or alloys

MDP 453 Composite Technology

  Ceramics: metallic + non-metallic elements
(C, N, O, P, S)

MDP 453 Composite Technology

  Polymers: constituting elements H, C, N, O, F, Si

MDP 453 Composite Technology

  Composites: combination of two or more materials

MDP 453 Composite Technology

 Composites
 Two or more materials, called constituents, are
combined in a configuration on macroscopic scale to
form a new material that combines the best features
of each constituent so as to maximize certain
properties.
– It is manufactured.
– It consists of two or more physically and /or chemically
distinct, suitably arranged or distributed phases with an
interface separating them.
– It has characteristics that are not depicted by any of the
constituents in isolation.

MDP 453 Composite Technology

 Composite related terminologies and general
classification
 Matrix: the continuous phase

 Reinforcement: the dispersed

phase

 Interface: Two dimensional

plane between reinforcement/
matrix

 Interphase: Coated phase or

interfacial reaction phase

MDP 453 Composite Technology

 1. The Reinforcement
 Function
– To enhance matrix properties
– Principle load bearing constituent
– Imparts stiffness and strength
– Restrain crack propagation in matrix
– Control the physical properties (Density, Conductivity, ...)
 Classification by the shape of materials
– Fibres, whiskers, particles, laminate, flakes,

MDP 453 Composite Technology

 2. The Matrix
 Function
– Transfer and distribute load to reinforcements
– Bind and distribute reinforcements
– Protect reinforcement from environmental atmosphere
– Give ductility and toughness
 Classification by the types of materials
– Metals, Ceramics, Polymers
=> MMC, PMC, CMC

MDP 453 Composite Technology

 3. Interface and Interphase
 Results from bringing fibre and matrix together
 Force transmission zone
 Influences composite properties

MDP 453 Composite Technology

 Classification of composite materials
 Based on the Reinforcing
Materials
1. Fiber Reinforced (or Fibrous)
Composites
2. Particle Reinforced (or
Particulate) Composites
3. Flake Composites
4. Filled (or Skeletal) Composites
5. Laminated (or Laminar)
Composites

MDP 453 Composite Technology

 Composites

Particle-reinforced Fiber-reinforced Structural

Large- Dispersion- Continuous Discontinuous Laminates Sandwich

particle strengthened (aligned) (short) panels

Aligned Randomly
oriented

MDP 453 Composite Technology

 Examples:

Sandwich
panels

MDP 453 Composite Technology

  Examples:
Fiber reinforced
composites

MDP 453 Composite Technology

 Examples: Particle reinforced MMC
Metal Matrix Composite in Fe-Ti-C.

SiC in Aluminium

MDP 453 Composite Technology

 Properties of Composite Materials
Composite Properties are affected by:
 Properties of reinforcing materials and matrix
materials
 Forms (shapes), arrangement and volume fractions of
reinforcing materials
 Interaction between constituents

 Composite properties arise from constituent

combination effects
 Three basic rules

MDP 453 Composite Technology

 a. Summation: Rule of Mixtures (ROM)

Summation of properties (P) of the individual

constituents, with respect to their volume
fraction (V)

Pc  Vr Pr  Vm Pm

• example: composite strength

 c  Vr r  Vm m
MDP 453 Composite Technology
 b. Complementation
 Each constituent compliments the other by
contributing separately with distinct properties.
 ex. Clad Material :
-> Surface-Corrosion Resistance
-> Interior-Strength

MDP 453 Composite Technology

 c. Interaction
 The property of one constituent is dependent on the
property or action of the other.
 The composite properties are usually intermediate
between those of the constituents or higher than
those of both.
 Example: CMC SiC/Si3N4: Fracture Toughness

MDP 453 Composite Technology

 Types of composite materials:
 1. fiber reinforced composites
 2. particle reinforced composites
 3. flake reinforced composites
 4. Filled composites
 5. Laminated Composites

MDP 453 Composite Technology

 1. Fibre Reinforced Composites (FRC)

Most effective for

strengthening

MDP 453 Composite Technology

 Fabrication of FRC

MDP 453 Composite Technology

 Advantages of FRC
 High specific strength
 High specific modulus (stiffness)
 High strength at elevated temperatures
 Low density
 Improved toughness, fatigue strength, creep
 Improved oxidation and corrosion resistance
 Controlled thermal expansion and conductivity
 Improved erosion properties
 Ability to tailor make specific properties

MDP 453 Composite Technology

 Factors affecting FRC properties
 Fibre
– Properties, orientation, length, shape
 Matrix
– Properties
 Fibre-Matrix interface
– Bonding, wetting
 Fibre-Matrix Interphase
– Interfacial reaction, coating, adhesive

MDP 453 Composite Technology

 2. Particle Reinforced Composites
(PRC)
a. Dispersion strengthened/hardened composites
– Matrix + fine particles -> act as dislocation barrier

MDP 453 Composite Technology

 2. Particle Reinforced Composites (PRC)

Fabrication techniques
 Surface oxidation of ultra-fine powders & powder
processing
 Internal oxidation of dilute solid solution alloys
– Solute elements-oxidation
– eg. Cu + Al → Cu + Al2O3
 Mechanical alloying of fine metal powders and fine
oxide powders
 Atomization from liquid metal and powder mixture

MDP 453 Composite Technology

 2. Particle Reinforced Composites (PRC)

b. Particle reinforced composites

– Matrix + particles
 Fabrication techniques
– Powder Processing Technique
• Ceramic Particles + Metal Powders
• Metal Particles + Ceramics Powders
• Metal Particles + Polymer Powders
– Compocasting or Rheocasting
• Ceramic Particles + Melted Metal Matrix

MDP 453 Composite Technology

 2. Particle Reinforced Composites (PRC)

 Dispersed particles usually have a higher melting

point compared to matrix=> increased strength at
elevated temperatures

MDP 453 Composite Technology

 2. Particle Reinforced Composites (PRC)

c. Cermets
– Ceramic Particles + Metallic Phase (Binder)
 Fabrication techniques
– Powder Processing Technique → Liquid phase
Sintering

MDP 453 Composite Technology

 3. Flake Composites
 Isotropic properties in two dimensions
 Perpendicular direction to flake
– Almost no strengthening effect
– Increase in fluid penetration resistance
 Flake-flake contact increases electrical conductivity
isotropic anisotropic

MDP 453 Composite Technology

 3. Flake Composites

 Advantages compared to FRC

– Higher flexural modulus since flakes are free to bend in
only one plane.
– Uniform strength because isotropic in the plane of
flakes.
– Lower cost because flakes are less expensive to make
than glass fibres.

MDP 453 Composite Technology

 4. Filled composites
 Continuous three-dimensional structural matrix
infiltrated or impregnated with a second-phase filler
material
 Matrix - continuous honeycomb or spongelike
network → Framework
 Filler - continuous or discontinuous → Functional
Properties

MDP 453 Composite Technology

 5. Laminated Composites
 Arrangement of different sheets of films - bonded into
sandwich structure
 easy to control the design and properties by controlling
– Layer Thickness, Layer Orientation
 Increase in bend strength, impact energy, fracture
strength, fatigue strength due to
– Repeated initiation and propagation of cracks at interfaces
of each layer

MDP 453 Composite Technology

 Applications
 Spring Steel Strip
→ Camber (bending)
 Wood Board
→ Damping the spring action
 Al
→ Good bonding with steel
 Phenolic Plastic → Light,
easy sliding

MDP 453 Composite Technology

 Tailored properties
 Epoxy resin
– E = 35 GPa
– ρ = 1.2 g/cm3
 Graphite fibre
– E = 1000 GPa
– ρ = 2.6 g/cm3

Graphite/Epoxy Resin
• E = 306 Gpa
• ρ = 1.5 g/cm3

•Calculate the volume fraction of the constituents

MDP 453 Composite Technology

 Properties controlled over large range
 Variation of coefficient of
thermal expansion with
volume fraction of silicon
carbide particles in
Aluminium.

MDP 453 Composite Technology

 Composites in A3xx

MDP 453 Composite Technology

 Disadvantages of Composites
 High cost of fabrication of composites
 Mechanical characterization of a composite structure
is more complex than a metal structure
 Repair of composites is not a simple process
compared to that for metals
 Composites do not have a high combination of
strength and fracture toughness compared to metals
 Composites do not necessarily give higher
performance in all the properties used for material
selection: strength, toughness, formability, join-ability,
corrosion resistance, and affordability

MDP 453 Composite Technology

 Next lecture…
 Reinforcements

 Homework:
 For composite:
 Find applications and their components and
characteristics
 Bring some ppt or some slides next lecture

MDP 453 Composite Technology