MEK4540

Komposittmaterialer og konstruksjoner Composite materials and structures

Innledning materialer ensrettede kompositter Introduction materials unidirectional composites

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MEK4540 Teaching schedule

Normally lectures will be on Wednesdays from 12.15-14.00 and practice sessions will be on Thursdays from 12.15-14.00. However, there will be several deviations from this:
Lecture no. 2 will be held on Thursday 23.08.2012 in place of the practice session. There will be no lecture on Wednesday 29.08.2012. There will be a practice session on Thursday 30.08.2012. There will also be deviations in September and early October.

The full schedule will be published within 1-2 days.

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Preliminaries
Language:
PowerPoint presentations in English Text books in English Norwegian + English technical terms will be provided where possible Spoken language Norwegian or English Assignments (obligs) handed out in English Students may hand in solutions in English or Norwegian Written or oral examination in Norwegian or in English if requested

Text books:
Main text: B.D. Agarwal, L.J. Broutman and K. Chanrashekhara: Analysis and Performance of Fiber Composites, 3rd ed. Composite plates additional material: D. Zenkert and M. Battley: Foundations of Fibre Composites Ch. 5 and parts of Ch. 8 to be handed out Sandwich beams and plates: D. Zenkert: Introduction to Sandwich Construction (student edition KTH)
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Course content Kursets innhold

Introduction and definitions Component materials Unidirectional composites Orthotropic lamina (plies) and laminates Laminated plates (bending and buckling) Composites in ANSYS Sandwich materials Sandwich beams and plates Joints Short fibre composites Production methods Mechanical testing Design criteria and rules Innledning og definisjoner Materialkomponenter Ensrettede kompositter Ortotrope lag og laminater

Laminerte plater (byning og knekning) Kompositter i ANSYS Sandwichmaterialer Sandwichbjelker og -plater Sammenfyninger Kortfiberkompositter Produksjonsmetoder Mekanisk prving Dimensjonering og regelverk

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Definitions
A composite material is a material that consists of one or more discontinuous components (particles/fibres/reinforcement) that are placed in a continuous medium (matrix)

In a fibre composite the matrix binds together the fibres, transfers loads between the fibres and protects them from the environment and external damage. The fibres carry the loads.
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Main classes
Particulate composites
Various geometrical shapes (cubes, spheres, flakes, etc.) Various materials (rubber, metal, plastics, etc.) Have generally low strength. Will not be treated further in this course.

Fibre composites
Discontinuous or Continuous

See next slide for further divisions

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Classification of composite materials

From Agarwal, Broutman & Chanrashekhara

and multi-layered composites having same properties in each layer

Layers with different materials

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Microscopy

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Composites properties

UD = unidirectional = ensrettet QI = quasi-isotropic = kvasi-isotrop

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Applications

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Offshore/subsea
Tension leg, tether

Riser

Subsea protection cover

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Offshore/subsea

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Ships/boats

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Naval ships

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Sports and leisure equipment

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Cars

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Trains (Flytoget)

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Aircraft

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Composites in Airbus designs

Source: http://www.mscsoftware.com/events/vpd2007/emea/presentations/Session-2A-AIRBUS-Bold.pdf
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Composites in Airbus designs

Source: http://www.mscsoftware.com/events/vpd2007/emea/presentations/Session-2A-AIRBUS-Bold.pdf
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Materials in Boeing 787 Dreamliner

Source: http://www.boeing.com/commercial/aeromagazine/articles/qtr_4_06/article_04_2.html
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Aircraft development over the years

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Wind energy
The blades can be as long as 62 m

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Buildings and bridges

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British naval vessels in GRP

HMS Sandown

HMS Wilton

GRP is used here for its non-magnetic properties

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Sandown class mine-hunter

Midship section

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Sandwich catamarans (SES)

Midship section

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Visby Class Swedish Navy

72 m long CFRP sandwich with PVC core

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Materials glass fibres

Types: E-glass (+ S-glass, C-glass and D-glass) Production method
Spun from molten glass

Properties
Low cost Moderately high strength Low stiffness Low wear resistance Sensitive to moisture Sizing (coating / surface preparation): 2 types/purposes:
To protect the fibres and keep them together during further processing (weaving etc.). Removed before use. To improve adhesion (also called coupling agents) organofunctional silanes
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Materials carbon fibres

Carbon and graphite fibres
Graphite fibres: 99% Carbon Carbon fibres: 8095% Carbon

Production
Organic fibres: PAN, rayon and pitch Stretched and stabilised at 200C Pyrolysis at 1500C (inert atmosphere) Grafitisation at 3000C (inert atmosphere)
strong covalent bonds in longitudinal direction of fibre.

Important to note
Carbon fibres can be of several types, with widely differing properties. Normally supplied with sizing for use with epoxy resins use with polyester and vinylester requires special sizing.
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Materials other fibre types

Aramid (Kevlar, Twaron)
Aromatic polyamide Spun from solution in acid

HPPE High performance polyethylene

UHMW-PE ultra-high-molecular-weight polyethelene Spun from solution and then stretched Dyneema and Spectra Properties roughly similar to aramid

Boron, SiC

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Fibre properties
Tensile modulus [GPa] E-glass High-stiffness carbon High-strength carbon Kevlar 49 UHMWPE 72 500-800 250-350 124 118 Tensile strength [MPa] Tensile strain at failure [%] Density [g/cc] 2.5 2 1.8 1.4 0.97

2000 -2500 3 2100 3100-4500 3600 2500 0.9-1.8 0.3-0.4

NB: Carbon fibres are available with a wide range of properties!

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Reinforcement architecture
UD fabric or tape Multiaxial non-crimp knitted fabric straight fibres i layers with defined directions, stitched together Woven fabric fibres in 0/90 directions, not straight Chopped strand mat (CSM) short fibres randomly oriented Continuous strand mat long fibres randomly oriented

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Matrix materials polymers

Poly = many Mer = part E.g. polyethylene [- CH2 CH2 -]n Linear Branched Cross-linked

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Matrix materials
Thermoplastics
Polyethylene (PE), polypropylene (PP) (=polyolefin), PMMA, PVC, PS, ABS, PC, POM, PET, TPU Linear or branched molecule chains (are not chemically bound to each other) Can be melted down and re-used

Thermosets
Polyester (unsaturated), Epoxy, Vinylester, Polyimide, Phenolic Cross linked chains are chemically bound to each other Cannot be melted down and re-used Supplied as prepolymer (resin) which hardens when initiator or hardener is added.

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Polymer mechanical properties temperature dependence

Tg = glass transition temperature Tm = melting temperature

Thermoplastic, amorphous Linear or branched chains Transparent PS, PC, PMMA Can only be used at T<Tg
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Thermosets Crosslinked chains Used at T<Tg

Semi-crystalline Not transparent Normally linear chains Can only be used at T<Tm Brittle at T<Tg

Unsaturated polyester
Prepolymer: Linear chain dissolved in styrene
Styrene participates in curing process and reduces viscosity Addition of inhibitors and accelerators

Production of polyester resin

Saturated dibasic acid Phthalic acid anhydride most used, cheapest Isophthalic acid Adipin acid flexibility Unsaturated dibasic acid Fumaric acid Maleic acid Glycol Propylene glycol most used Ethylene or diethylene glycol

Curing: Styrene, retarded by inhibitor, addition of initiator results in cross linking

Addition polymerisation, no by-products, EXOTHERM Styrene HMS for open processes

Tighter cross-linking gives higher Tg, but a more brittle material

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Epoxy
Epoxy group Linear prepolymer (resin)
Ordinary Epichlorohydrin + Bisphenol A = DGEBA Curing system cross-linking Polyamines cured at room temperature
Curing by additive polymerisation no by-products

Carboxyl acid anhydride cured at 100-180C

Complex reaction gives (small amounts) H2O as by-product but high temperature expels water.

Merkapto
Low temperature, rapid curing

Exotherm HMS - allergies

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Vinylester
Chemical structure resembles epoxy, but cured as polyester Prepolymer based on DGEBA + organic acid dissolved in styrene or other monomer Also found as rubber-modified vinylester with high strain to failure.

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Properties of matrix materials

Tensile modulus [Gpa] Polyester 2-4 Tensile strength [MPa] 30 - 100 Density [g/cc] 1.3 Tmax [C] 40-90

Vinylester

3.0-3.5

70 - 80

1.2

~100

Epoxy

3-4

50 - 130

1.2

160

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Properties of fibre composites

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Properties of UD (uni-directional) composites

Following must be studied: Fibre content by both volume and weight Stiffness
E-modulus in both longitudinal and transverse directions G-modulus Poissons ratio

Strength
tension, compression, shear various directions

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Nomenclature
m matrix f fibre, reinforcement c composite 1 longitudinal direction 2 og 3 transverse direction 1,2,3 also denoted L,T,T Laminate composite built up from several layers, often with fibres in different directions UD ply layer with all fibres in same direction
Properties are different in transverse and longitudinal directions
ply laminate

UD composite all plies have same fibre direction Other possibilities:

Layers with fibres in 2 perpendicular directions (e.g. woven fabrics) cross-ply Laminate with layers in several directions

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UD composites: Volume and weight fractions

Ratio between amounts of fibre and matrix can be described by use of fibre volume fraction or fibre weight fraction Has importance for mechanical properties Volume fraction
vc vm vf volume of composite volume of matrix volume of fibres

Weight fraction
wc wm wf weight of composite weight of matrix weight of fibres

vc = v f + v m

wc = w f + wm

Definition of volume fractions: vf v Vf = Vm = m vc vc

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Definition of weight fractions:

Wf = wf wc Wm = wm wc

Relationships between densities, volume and weight fractions v w

Vf =
f

vc

Vm =

vm vc

Wf =

wc

Wm =

wm wc

Relationship between densities c , f , m

wc = w f + wm

=> =>

c vc = f v f + m v m vf v c = f + m m vc vc = f V f + mVm

=> =>

vc = v f + v m wc w f wm = +

m
+

w f wc

wm wc

= W f f + Wm m

Relationship between weight and volume fractions:

Wf = wf wc =

f vf c vc

f c

Vf

We have also the void fraction

Vv =

Wm =
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m Vm c

ct ce ct

Strength and stiffness in longitudinal (fibre) direction

Assumptions: Fibres are
uniform wrt. properties and diameter continuous and parallel through entire composite

Perfect adhesion between matrix and fibres. Pf, Pm, Pc are the respective forces Af, Am, Ac are the respective areas Respective strains are equal, f = m = c
Pc = Pf + Pm

Then we have
i.e. => =>

Pc = c Ac = f A f + m Am

c = f

Af Ac

+ m

Am Ac

c = f V f + mVm

since

Vf =

Af Ac

Vm =

Am Ac

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Linear elastic case

Differentiate wrt. strains:
d c d f d m = Vf + Vm d d d

=> Ec = E f V f + E mVm

contributions from fibres and matrix are proportional to volume fractions. How much of the forces are taken up by the fibres?
f = m = c
f
Ef
Ef Ec

=>
f c
=

m
Em

c
Ec

=>

f m
Pf

=
=

Ef Em

and

=> P m
and

f Af m Am

Ef Vf E m Vm

Pf Pc

f Af f A f + m Am

(E f

E f Em E m + Vm V f

) (

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Non-linear elastic case

Generally a composite deforms according to linear theory. The deformation sequence is as follows:
1. Fibres and matrix undergo linear elastic deformation. Following still applies:

E c = E f V f + E mVm
2. Fibres deform linearly while matrix enters a non-linear phase:

Ec = E f V f +
3. 4.

Both fibres and matrix deform non-linearly but following still applies: c = f V f + mVm Fibres fracture, resulting in fracture of the composite.

d m Vm d m

Several possible types of failure dependent on fibre fraction and fibre brittleness:

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Strength and stiffness in longitudinal direction (contd.)

Vmin = min. fibre volume fraction for composite
fracture to be determined by fibre fracture as opposed to matrix fracture For V f > Vmin : fibre fracture => composite fracture because matrix cannot resist the load after fibres have failed. Then max. stress in composite is:
cu = fuV f + ( m ) (1 V f
f

For V f < Vmin : fibre fracture does not give composite fracture beause matrix can still resist the load. We assume the fibres do not carry forces when > f. Then max. stress in composite is:
cu = mu (1 V f

To find Vmin we equate these, so that

V f = Vmin :

Vmin =

fu + mu ( m )

mu ( m )

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Strength and stiffness in longitudinal direction (contd.)

V f < Vmin gives composite strength that is lower than matrix strength mu, while V f > Vmin can give either higher or lower. More useful to define volume fraction Vcrit that gives lower strength limit mu : mu ( m ) cu = fuV f + ( m ) (1 V f ) mu i.e. Vcrit = fu ( m )
f

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