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Atomic scale:-
At atomic scale, composites are usually:
Metal alloys, polymers, Al-Cu alloys, Al-Si alloys, Al-Zn alloys and iron
alloys.
Microstructure:-
Iron accommodating 0.2% carbon is a composite of ferrite and pearlite.
Macrostructure:-
GFRP: Glass Fiber Reinforce Plastics (used in the manufacturing of boats,
automotive cylinders)
GFRPMC: Glass Fiber Reinforce Polymeric Matrix Composites.
These are structural composites.
Types:-
There two types of composites:
Matrix composites
Reinforcement
Matrix composites:-
Most common matrix composites are:
MMC: Metal Matrix Composite.
PMC: Polymer Matrix Composite.
CMC: Ceramic Matrix Composite.
Metal matrix composites are usually made up of aluminium to give
it enough strength as it is less dense than iron so used in aerospace.
Reinforcement:-
Reinforcement composites are usually fibers.
Glass fibers
Carbon fibers
Aramid fibers
Fibers are usually strengthy, low density, resistant to heat, corrosion,
electricity, cheap, easy to handle and easily available.
(A)-Glass fiber:-
These are mainly continuous fibers and made by drawing or
extrusion method. They are structural composites. Glass fiber is cheaper
than others but has high density. It is widely used. For example: CNG
cylinders and bus bodies.
They have greater tensile strength and less compressive strength.
Types:-
There are two types of glass fibers:
S-type: they have high strength. Example: Al2O3 (50-45%), SiO2 (10-15%),
MgO (10%). Here Al2O3 and MgO are expensive. It is 650kps.
E-type: These are electrical structural composites usually steel bars.
Example: lime-aluminum borosilicate glass (CaO, Al2O3, B2O3, SiO2). E-type
is cheaper than S-type because of SiO2. It is 500kps. (103 pounds = 1 kips)
Matrix (Plastic):-
Plastics are C-C bonded, long chained molecules. These are organic
polymers.
Properties:
Low strength
Low density
High compressive strength
Low melting point
Types:-
Epoxy resin
Polyester
• Concrete, metal and wood are replaced by composites now
days.
Concrete:-
Concrete is an example of ceramic composite which consists of granular
aggregate embedded in Portland cement.
In general concrete is a mixture of mineral aggregate, water and cement forming
a workable mass.
Aggregate consists of sand (fine particles: diameter less than 6mm) and gravel
(coarse particles: diameter more than 1.8mm).
Overall production of concrete is more than steel.
Properties:-
It has 10 times more compressive strength than tensile strength.
Its density is much higher than structural composites.
It is economically available material.
It is resistant to heat.
It’s easy to fabricate on required site.
It is easy to cast.
Matrix in concrete:-
Cement acts as a matrix phase in it as well as a binder to hold granular
aggregate together.
2CaSiO2:-
It gives strength to concrete after 1 week of setting in specific environment.
Grades of cement:-
There are 5 grades of cement for different applications obtained by adjusting the
percentages of raw materials.
Compressive Strength
7 90
Days
Reaction:-
The mineral aggregate is taken of proper size and a paste of cement and water is
added in it. The chemical reaction between cement and water is simple hydration
while there is no chemical reaction between cement and gravel. The paste of
cement and water just binds the mineral aggregate strongly. After setting and
drying, the mass structure becomes very strong.
Proportioning:-
Here cement is the most expensive one while gravel is less expensive than
cement. Sand is the cheapest one among them all.
Air is also present: 0.5 to 8 %.
Reinforced Concrete:-
It is made by casting concrete on steel rods. Since the surface of steel bars is
usually rough so concrete sets on it with good mechanical strength.
Compressive strength of concrete is 55000 psi while tensile strength of steel is
40000 to 80000 psi so these two materials give much better properties when
combined to form a composite.
When steel bars are put in tension, properties become much better. Thos
property is called work hardening.
Wood:-
It is a natural composite and is composed of cellulose chain. These longitudinal
chains are bound together by amorphous lignin. Wood has fibrous structure and
hence has greater strength in longitudinal direction than in the transverse.
Matrix: cellulose
Reinforcement: lignin
Types:-
Soft wood: It is obtained from ever green trees.
Hard wood: It is obtained from seasonal trees.
Slip Casting:-
Slip casting is perhaps the best known of the ceramic matrix composite.
First we start out with a slip, which is composed of ceramic particles
(usually clay) dispersed in water.
We then pour the slip into a clay or plaster of Paris mold of the desired
shape.
The porous mold sucks up the water in the slip through capillary action,
thus depositing the slip on the walls of the mold.
Depending on how long one casts, one can create solid or hollow objects.
The resultant body is hard and dry to the touch but is very brittle and bears
little or no resemblance to the finished article but it is now ready to be
transformed in the kiln.
Metal Matrix Composite:-
"It is a material in which continuous carbon, silicon carbide, or ceramic fibers are
embedded in a metallic matrix material.”
Most common MMC’s are Aluminium Matrix Composites.
In general, the major advantages of Aluminium Matrix Composites
(AMC’s) compared to unreinforced materials, such as steel and other common
metals, are as follows:
Increased specific strength
Increased specific stiffness
Increased elevated temperature strength
Improved wear resistance
Lower density
Good corrosion resistance
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Sieve Analysis
A sieve analysis is a practice or procedure used for any type of non-organic or
organic granular round materials including sands, clays, granite, feldspars, coal,
soil, etc. It can also be used for grain and seeds.
Apparatus Required:-
Test Procedure:-
A series of circular sieves with a wire mesh cloth are nested involving
eight to nine sieves. This is typically called a column. They also have a
fixed height.
Wire mesh cloth are defined by their number of openings per inch. For
example a 14 mesh will have 14 openings per inch; a 12 mesh will have
12 opening per inch, and so on. The higher the mesh number the smaller
a particle has to be to pass through the column.
A sample is taken and split in a "splitter." The sample is then poured into
the top sieve which has the smallest number of openings per inch. The
next sieve than has more openings per inch. Traveling down the column
the opening per inch on each wire mesh cloth increases. The last "sieve"
is a round container much like a baking pan, and is called "the pan."
After the shaking is complete each sieve with its material sitting on its
cloth is then measured in a unit of weight (usually grams).
With the total weight the weight of the sample of each sieve is then divided
by the total weight to give a percentage sitting on each sieve.
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