Questions:

1. Even though there are many advantages with composites, they are not very common
as conventional metallic materials; give reasons.
2. What are the three important characteristics of fibres that contribute for higher
performance in the case of composite materials?
3. Give any two engineering applications for each type of composite materials.
4. Briefly explain the important characteristics of composite materials.
5. Briefly discuss the classification of composite materials.
6. Give any five important advantages and limitations of composite materials.
7. What are the functional requirements of reinforcement and matrix?
8. Discuss the effect of reinforcement on overall performance of composites.

Answers:
1. Reasons:
1.1. Cost:
1.2. Processing difficulty
1.3. Availability

2. Important characteristics of fibre:

2.1. Flexibility
2.2. Size
2.2.1. Large Particle reinforced: The term “large” is used to indicate that
particle–matrix interactions cannot be treated on the atomic or
molecular level; rather, continuum mechanics is used. The matrix
transfers some of the applied stress to the particles, which bear a
fraction of the load.
2.2.2. Dispersion-strengthened composites: Particles are normally much
smaller, with diameters between 0.01 and 0.1 m (10 and 100 nm).
Particle–matrix interactions that lead to strengthening occur on the
atomic or molecular level. Whereas the matrix bears the major portion
of an applied load, the small dispersed particles hinder or impede the
motion of dislocations. Thus, plastic deformation is restricted such that
yield and tensile strengths, as well as hardness, improve.
2.3. Aspect Ratio
2.4. Less defects
2.5. Heterogeneity

3. Engineering Applications:
3.1. Polymer Matrix Composites (PMC):
3.1.1. Body Armor Application: [2]
There is an increased demand for lightweight, flexible, and robust
body armors that can provide improved ballistic protection especially against
the increasingly lethal threats that soldiers will be exposed to. CNTs and
graphene, play a key role in creating ultra-strong, enormous energy absorber,
lightweight, and tough composites for the fabrication of the upcoming body
armors.
 Unlike the usual structural composites which typically contain up to 60
v% fibers, ballistic PMCs comprise higher volume fractions (about 80 v%)
Matrix: polybeta-amino-ester (PBAE)/ Polyamide (PA)
Reinforcement: CNTs, Kevlar

3.1.2. Wear resistant composites for automobile brake systems: [3]

Tailoring of the friction, wear, mechanical strength, thermal
characteristics of friction composites would be critical to develop new material
concepts for applications in automobile brake systems.

3.2. Metal-matrix composites (MMCs):

3.2.1. Truss elements, bus panels, antennas, wave guides in
spacecrafts: [4]
In the nearearth orbit, typical spacecraft encounter naturally occurring
phenomena such as vacuum, thermal radiation, atomic oxygen, ionizing
radiation, and plasma. Composite materials, with their high specific stiffness
and low coefficient of thermal expansion (CTE), provide the necessary
characteristics to produce lightweight and dimensionally stable structures.
Reinforcement/Matrix: Boron/aluminum (B/Al), graphite/aluminum (Gr/Al),
and graphite/magnesium (Gr/Mg)
3.2.2. MMCs for aeroengines: [5]
In components such as blades and vanes, compressor blings, shafts,
struts and links, etc. that require high specific stiffness, good fatigue
properties, mechanical and thermal properties.
Composite:
- Ti Alloy matrix reinforced with large diameter (~140um) SiC
monofilament.
- Fine SiC particles (~12um) powder blended or mechanically alloyed
with AA 2000 and 6000 series alloy powders.

3.3. Ceramic-matrix composites (CMCs):

3.3.1. Ceramic Composite Development for Gas Turbine Engine Hot
Section Components: [6]
Ability of material to display 3-dimensional strength properties that
sufficiently exceed the stresses that can arise, and the ceramic material
should maintain the strength advantage under the maximum temperatures for
components such as Combustor Liner, Turbine Shroud, Vane and Blade.
Reinforcement/Matrix: SiC/SiC CMC

3.3.2. CMCs in Liquid Rocket Engine (LRE) applications: [7]

 Combustion materials in LREs require compatibility with cryogenic
propellants, high-temperature, chemical corrosion, oxidation resistance, high
thermal conductivity and abrasion resistance.
All-Oxide Ceramic Composites based on Al2O3 Fibres and
Alumina–Zirconia Matrix

4. Important characteristics of composite materials:

● Heterogeneity
● Anisotropy
● Hierarchy
● Symmetry
Or
● Corrosion resistance
● High specific strength
● High specific stiffness
● Good Abrasion resistance
● Good Impact resistance

5. Classification of composite materials:

The broad classification is based on the constituent materials in a composite, namely

Matrix based and Reinforcement based.
A. Matrix based:
a. Polymer-matrix composites (PMCs)
They consist of a polymer resin as the matrix, with fibers as the
reinforcement medium. They have a diversity of composite applications due
to their room-temperature properties, ease of fabrication, and cost. The PMC
can further be classified based on the type of reinforcement added, such as:
i. Glass Fiber-Reinforced Polymer (GFRP) Composites
ii. Carbon Fiber-Reinforced Polymer (CFRP) Composites
 iii. Aramid Fiber-Reinforced Polymer Composites
iv. Other reinforcements such as boron, silicon carbide, and aluminum
oxide.
b. Metal-matrix composites (MMCs)
The matrix is a ductile metal. These materials may be utilized at
higher service temperatures than their base metal counterparts. Some of the
advantages of these materials over the PMCs include higher operating
temperatures, nonflammability, and greater resistance to degradation by
organic fluids.The reinforcement may be in the form of particulates, both
continuous and discontinuous fibers, and whiskers; concentrations normally
range between 10 and 60 vol%.
c. Ceramic-matrix composites (CMCs):
Ceramic materials are inherently resilient to oxidation and
deterioration at elevated temperatures; were it not for their disposition to
brittle fracture, some of these materials would be ideal candidates for use in
high-temperature and severe-stress applications, specifically for components
in automobile and aircraft gas turbine engines. Crack initiation normally
occurs with the matrix phase, whereas crack propagation is impeded or
hindered by the particles, fibers, or whiskers.

B. Reinforcement based:
a. Whisker reinforced:
Whiskers are very thin single crystals that have extremely large
length-to-diameter ratios. As a consequence of their small size, they have a
high degree of crystalline perfection and are virtually flaw free, which
accounts for their exceptionally high strengths; they are among the strongest
known materials. In spite of these high strengths, whiskers are not utilized
extensively as a reinforcement medium because they are extremely
expensive. Moreover, it is difficult and often impractical to incorporate
whiskers into a matrix. Whisker materials include graphite, silicon carbide,
silicon nitride, and aluminum oxide.
b. Particle reinforced:
i. Large Particle reinforced:
The term “large” is used to indicate that particle–matrix
interactions cannot be treated on the atomic or molecular level; rather,
continuum mechanics is used. The matrix transfers some of the
applied stress to the particles, which bear a fraction of the load.
ii. Dispersion-strengthened composites:
Particles are normally much smaller, with diameters between
0.01 and 0.1 m (10 and 100 nm). Particle–matrix interactions that lead
to strengthening occur on the atomic or molecular level. Whereas the
matrix bears the major portion of an applied load, the small dispersed
particles hinder or impede the motion of dislocations. Thus, plastic
deformation is restricted such that yield and tensile strengths, as well
as hardness, improve.
c. Fiber reinforced:
A critical fiber length is necessary for effective strengthening and
stiffening of the composite material. This is called the critical length (Lc).
 Fibers for which fiber length L>>Lc (normally L>15Lc) are termed continuous;
discontinuous or short fibers have lengths shorter than this. For discontinuous
fibers of length significantly less than Lc,the matrix deforms around the fiber
such that there is virtually no stress transference and little reinforcement by
the fiber.
d. Structural composites:
are combinations of composites and homogeneous materials, the
properties of which depend not only on the properties of the constituent
materials but also on the geometrical design of the various structural
elements.

6. Composite Materials:

Advantages Limitations

High specific strength Moisture absorption

High specific stiffness Difficulty in machining

NVH resistance Toxicity

High toughness High cost

Corrosion resistance

7. Functional Requirements of Reinforcements and matrix (expand on each

point):

7.1. Reinforcements: High aspect ratio, compatibility, thermal stability, load

carrying capacity, stiffness

7.2. Matrix: Good flow, low CTE, reduced moisture absorption

References:
1. Materials Science and Engineering: An Introduction, 6th Edition William Callister, Ch
06
2. Zineb Benzait and Levent Trabzon (2018), ‘A review of recent research on materials
used in polymer–matrix composites for body armor application’, Journal of Composite
Materials, 0(0) 1–23
3. Nandan Dadkar, Bharat S. Tomar, Bhabani K. Satapathy (2009), ‘Evaluation of
flyash-filled and aramid fibre reinforced hybrid polymer matrix composites (PMC) for
friction braking applications’, Materials & Design, Volume 30, Issue 10, pp4369-4376
4. Rawal, S.P. Metal-matrix composites for space applications. JOM 53, 14–17 (2001).
5. J.A. Hooker and P.J. Doorbarm (2000), ‘Metal matrix composites for aeroengines’,
Materials Science and Technology, Vol 16, No.7-8, pp725-731.
6. DiCarlo, JA, & van Roode, M (2006) "Ceramic Composite Development for Gas
Turbine Engine Hot Section Components." Proceedings of the ASME Turbo Expo
2006: Power for Land, Sea, and Air. Volume 2: Aircraft Engine; Ceramics; Coal,
Biomass and Alternative Fuels; Controls, Diagnostics and Instrumentation;
Environmental and Regulatory Affairs. Barcelona, Spain. May 8–11, 2006. pp.
221-231.
7. Bach, Christian, Frank Wehner, and Jan Sieder-Katzmann. 2022. "Investigations on
an All-Oxide Ceramic Composites Based on Al2O3 Fibres and Alumina–Zirconia
Matrix for Application in Liquid Rocket Engines" Aerospace 9, no. 11: 684