COMPOSITES

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Definition

A composite is a
combination of two or
more simple materials to
get another material with
better properties
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Examples

Wood (a natural composite comprising cellulose fibers in a
lignin and hemicellulose matrix )

Cemented carbides (WC with Co
binder)

Plastic molding compounds
containing fillers

Rubber mixed with carbon black
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Components in a Composite
Material
All composite materials consist of
two phases:
1. Primary phase called the matrix
2. Secondary phase (or) imbedded
phase also called a reinforcing
agent.

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Functions of Matrix Material

(Primary Phase)
Provides the bulk form of the composite
material
Holds the imbedded phase in place, usually
enclosing and often concealing it
When a load is applied, the matrix shares
the load with the secondary phase, in some
cases deforming so that the stress is
essentially born by the reinforcing agent
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Functions of Particle Material

(Secondary Phase)
It reinforces the primary phase
It takes the form of an infiltrated
phase in a skeletal or porous matrix
Example: a powder metallurgy part
infiltrated with polymer

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Possible physical shapes of imbedded (secondary)

phases (a) fiber, (b) particle & (c) flake

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 The matrix phase is continuous ,

soft , ductile, almost clay-like and
surrounds the fiber phase.
The fiber (or particle) phase is
typically much stronger than the
matrix.
Together, the two phases can give a
material that has better properties.

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Why Composites are Important

Composites are
very strong
stiff
very light in weight
( so ratios of strength-to-weight and
stiffness-to-weight are several times greater than
steel or aluminum )
Better Fatigue
Greater Toughness
They do not corrode
Possible to achieve combinations of properties
which cannot be obtained with metals, ceramics,
or polymers alone
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Classification
Based
Based
Based
Based

on
on
on
on

Source
Primary Phase
Secondary Phase
Orientation of Fibre

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Source

Traditional

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Synthetic

Source
1. Traditional composites
composite materials that occur in nature or have
been used by civilizations for many years

Examples: wood, concrete, asphalt

2.Synthetic composites
modern material systems normally associated
with the manufacturing industries, in which
the components are first produced separately
and then combined in a controlled way to
achieve the desired structure, properties, and
part geometry
Examples : FRP
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Primary Phase

Matrix

Metal
(MMC)

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Plastic
(PMC)

Ceramics
(CMC)

Based On Primary Phase

1. Metal Matrix Composites (MMCs) mixtures of ceramics and metals, CERMETS
example cemented carbides
2. Polymer Matrix Composites (PMCs)
- thermosetting resins are widely used in PMCs
Examples: epoxy and polyester with fiber
reinforcement, and phenolic with powders
3. Ceramic Matrix Composites (CMC s)
Examples : Al2O3 and SiC imbedded with fibers to
improve properties and find use in high
temperature applications (It is the least

common composite matrix)

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Secondary
Phase
Particulate
Composite

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Layered
Composite

Fibre Reinforced
Composite

Based on Secondary Phase

1.Particulate Composites
Example : W ThO2 , Cermets , Concrete
2. Layered Composites
Example : Plywood , Copper Clad Stainless steel
vessels
3. Fibre Reinforced Composites:
Example : Glass Reinforced Plastics , Aluminium
Boron Composites
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Fiber Orientation

One Dimension

Two dimension
(Planar)

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Three
Dimension
(Random)

Based on Orientation of Fibre

One-dimensional reinforcement, in which
maximum strength and stiffness are obtained
in the direction of the fiber
Two Dimensional, in some cases in the form
of a planar woven fabric
Three-dimensional ( Random) in which the
composite material tends to possess isotropic
properties

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a) One (b) Two ( c ) Three

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One Dimension

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Two Dimension

Polymer Matrix Composites

Primary Phase is Polymer
Secondary Phase may be Fibre /
Particle / flakes
Commercially PMCs are more
important than MMCs or CMCs
Examples:
most plastic molding compounds
rubber reinforced with carbon black
Fibre-Reinforced Polymers (FRPs)

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Fibre Reinforced Plastics

(FRP)
FRPs are most closely identified with
the term composite
Primary Phase : Polymer
Usually a thermosetting (TS) plastic
such as unsaturated polyester or epoxy
Can also be thermoplastic (TP), such as
nylons (polyamides), polycarbonate,
polystyrene, and polyvinylchloride

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Secondary Phase : Fibre

Principal fiber materials in FRPs are glass,
carbon, and Kevlar 49
Less common fibers include boron, SiC,
and Al2O3, and steel
Glass (in particular E-glass) is the most
common fiber material; its use to reinforce
plastics dates from around 1920
Fibre can be discontinuous (chopped),
continuous
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Common FRP Structure

Most widely used form of FRP is a laminar structure, made
by stacking and bonding thin layers of fiber and polymer
By varying fiber orientation among layers, a specified level of
anisotropy (elasticity) in properties can be achieved in the
laminate

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Properties of FRP
Excellent strength-to-weight and
modulus-to-weight ratios
Low specific gravity (FRP weighs only about
1/5 as much as steel)
Good fatigue strength
Good corrosion resistance
Low thermal expansion - for many FRPs,
leading to good dimensional stability
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Applications
Aerospace the structural weight of
airplanes and helicopters consist of FRPs
Automotive body panels for cars and
truck cabs
FRP is used for boat hulls since the
1940s
Sports and recreation
fishing rods, tennis rackets, golf club
shafts, helmets, skis, bows and arrows.
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Some Important Fibre

Reinforced Polymer
Composites

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Glass FRP
Primary Phase :Nylon , Polyester etc.,
Secondary Phase : Long and Short Glass
Fibres
Properties: Low density, High Tensile
Strength ,High Impact Resistance,
Excellent Resistance to corrosion and
chemicals, low stiffness and low rigidity
Limitations: Cannot be used for a wide
range of temperature and as structural
material
Applications: Automobile parts, Storage
tanks, Flooring,Pipes
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Carbon FRP / High Performance

composites / Advanced Polymer Matrix
Composites
Primary Phase :Epoxy resin
Secondary Phase :Graphite fibre
Properties: Excellent Corrosion resistance , Very
light Thermal stability
Limitation: Very Expensive
Applications: Structural component of air borne
automobiles, Fishing rods, Golf club etc.,
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Aramid FRP
Primary Phase : Polymer
Secondary Phase ; PPTA Poly para
phenyl tere phthalamide (Kevlar)
Properties: High Toughness , high
Strength and ultra high modulus, Good
thermal and wear properties.
Limitations: Low resistance for axial
compression , Hygroscopic
Applications ; automobile break and
clutches, Structural material for aircraft ,
fire proof dress
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Other Important Composites

Alumina Reinforced Metal Composite

(type 1)
Primary Phase : Al alloy
Secondary phase : Alumina fibre
Properties : Low Density , Good wear
resistance and good dimensional stabiliity
Applications : Components of automobile
engine

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. Alumina composite ( type 2)

Primary Phase : Ni and Co based

alloys
Secondary Phase : Alumina
Properties: Excellent impact
resistance , Good creep and
rupture resistance , Good thermal
stability
Applications: Components of
turbine engine.

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Nano FRP Composites

Nano composites are a New Class of
Materials
Adding nano particulates to a polymer
matrix can enhance its performance
This strategy is particularly effective in
yielding high performance composites

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 Polymer nanocomposites are plastic

materials with small amounts of clay
added to them.
Specifically, a few molecules of clay are
sandwiched between miniscule layers of
plastics (polymers), resulting in a 'super
material' with numerous enhanced
properties such as greater strength,
higher resistance to permeability and
higher heat stability

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Used in food packaging, automobile parts

and medical devices
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.Nano composites
Superthermites are nano composite made
of silica and other metal oxides matrix with
Al as reinforcing agent
They are used as power tool housings,
mower hoods and covers for portable
electronic equipment such as mobile
phones, pagers etc

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