Material Science

Prof. Satish V. Kailas
Associate Professor Dept. of Mechanical Engineering, Indian Institute of Science, Bangalore – 560012 India

Chapter 12. Composites
Learning objectives: To know the different class of materials called composites To study different composites and their strengthening mechanisms with examples. To understand the importance and application of composites.

New class of materials. Bangalore – 560012 India Chapter 12. An engineer needs to have a very good knowledge about these materials for efficient use of composites. which are otherwise does not exist together. Indian Institute of Science. is thus emerged to serve the specific needs of modern technology. Thus it achieves properties of both the constituents. which are insoluble in each other. of Mechanical Engineering. Kailas Associate Professor Dept. Satish V. Basic conventional engineering materials are not able to serve the purpose. . A composite is made artificially and it contains at least two chemically distinct constituents.Material Science Prof. Composites Highlights. and also to develop a new category of composites. known as composites. This module is constructed with aim to explain the different composites and their strengthening mechanisms with examples. need for materials with special properties are growing. Motivation and Critical Concepts: With the invention and continued progress of modern technology.

Kailas Associate Professor Dept. their relative amounts. conventional engineering materials are unable to meet this requirement of special properties like high strength and low density materials for aircraft applications.1 Particle-reinforced composites This class of composites is most widely used composites mainly because they are widely available and cheap. Unfortunately. of Mechanical Engineering. For ease of recognition. differ in form and chemical composition and essentially insoluble in each other. However. emerged new class of engineering materials – composites. 12. Hence the following sections highlight the mechanics of composites. Millions of combinations of materials are possible and thus so number of composite materials. made by combining two distinct engineering materials in most cases. Composites are. Indian Institute of Science. one is called matrix that is continuous and surrounds the other phase – dispersed phase. Thus. The properties of composites are a function of the properties of the constituent phases. polymer matrix composites and ceramic matrix composites (2) size-and-shape of dispersed phase – particle-reinforced composites. there is no widely accepted definition for a composite material. Bangalore – 560012 India Chapter 12. which depend on size-andshape of dispersed phase. The constituent phases of a composite are usually of macro sized portions. It is understandable that properties of composite materials are nothing but improved version of properties of matrix materials due to presence of dispersed phase. thus. For the purpose of this module. fiber-reinforced composites and structural composites. Satish V. the following definition is adopted: any multiphase material that is artificially made and exhibits a significant proportion of the properties of the constituent phases.Material Science Prof. However. Composites There is a great need for materials with special properties with emergence of new technologies. composite materials are classified based on different criteria like: (1) type of matrix material – metal matrix composites. They are again two kinds: dispersion-strengthened and particulate- . and size-and-shape of dispersed phase. engineers need to understand the mechanics involved in achieving the better properties.

. These contain large amounts of comparatively coarse particles.reinforced composites. such as elastic modulus. Examples: thoria (ThO2) dispersed Ni-alloys (TD Ni-alloys) with high-temperature strength.1.01-0. of particulate composites achievable are in the range defined by rule of mixtures as follows: Upper bound is represented by: E c (u ) = E mVm + E pV p And lower bound is represented by: E c (l ) = Em E p E pVm + E mV p where E and V denote elastic modulus and volume fractions respectively while c. and p represent composite. m. while dispersoids hinder/impede the motion of dislocations. mechanism of strengthening is similar to that for precipitation hardening in metals where matrix bears the major portion of an applied load.e.2. Here the strengthening occurs at atomic/molecular level i.1. SAP (sintered aluminium powder) – where aluminium matrix is dispersed with extremely small flakes of alumina (Al2O3). Particulate reinforced composite Particulate composites are other class of particle-reinforced composites. matrix and particulate phases. and are of 0.1µm in size. In dispersion-strengthened composites. Particulate reinforced composite Figure 12. particles are comparatively smaller. Figure 12. A schematic diagram of these bounds is shown in the figure-12. Mechanical properties. These composites are designed to produce unusual combinations of properties rather than to improve the strength. These two classes are distinguishable based upon strengthening mechanism – dispersion-strengthened composites and particulate composites.

the highest strength and stiffness are obtained with continuous reinforcement. Its strength can be increased by additional reinforcement such as steel rods/mesh. The matrix material acts as a medium to transfer the load to the fibers.3: Schematic presentation of rule-of-mixture bounds. Polymers are frequently reinforced with various particulate materials such as carbon black. Concrete is most commonly used particulate composite. Eg. These composites are classified as either continuous or discontinuous. 12.Figure-12. Particulate composites are used with all three material types – metals. carbon black enhances toughness and abrasion resistance of the rubber. Discontinuous fibers are used only when manufacturing economics dictate the use of a process where the fibers must be in this form. The matrix also provides protection to fibers from external loads and atmosphere. It is also known as Portland cement concrete. Generally. more ductile matrix. stiff but brittle fibers into a softer. It consists of cement as binding medium and finely dispersed particulates of gravel in addition to fine aggregate (sand) and water.: tungsten carbide (WC) or titanium carbide (TiC) embedded cobalt or nickel used to make cutting tools. When added to vulcanized rubber. . polymers and ceramics. which carry most off the applied load. Cermets contain hard ceramic particles dispersed in a metallic matrix. Aluminium alloy castings containing dispersed SiC particles are widely used for automotive applications including pistons and brake applications.2 Fiber-reinforced composites Most fiber-reinforced composites provide improved strength and other mechanical properties and strength-to-weight ratio by incorporating strong.

rule-of-mixtures results in the following: σc =σm Af Am +σ f Ac Ac where Am/Ac and Af/Ac are the area fractions of the matrix and fiber phases respectively. if matrix and fiber are all of equal length. τc – interface bond strength. two extremes possibilities are – parallel alignment and random alignment. Thus. (a) Continuous fiber composites: Under longitudinal loading. d – diameter of the fiber.e. Effect of fiber orientation and concentration: with respect to orientation. Fibers for which l >> lc (normally l >15 lc) are termed as continuous. whereas discontinuous fibers are randomly or partially orientated. which is defined as: lc = σ*d f 2τ c σ*f – ultimate/tensile strength of the fiber.The mechanical properties of fiber-reinforced composites depend not only on the properties of the fiber but also on the degree of which an applied load is transmitted to the fibers by the matrix phase. isostrain condition. In the composite. σ c = σ mVm + σ f V f When the isostrain assumption is taken into account. their orientation and volume fraction in addition to direction of external load application affects the mechanical properties of these composites. discontinuous or short fibers on the other hand. Two instants of loading are: longitudinal loading and transverse loading. by assuming that deformation of both matrix and fiber is the same i. area fractions will be equal to volume fractions. Effect of fiber length: Some critical length (lc) is necessary for effective strengthening and stiffening of the composite material. Continuous fibers are normally aligned. Length of fibers. the above equation transforms into E cl = E mVm + E f V f = E m (1 − V f ) + E f V f The ratio of the load carried by the fibers to that carried by the matrix is given by Ff Fm = E fVf E mVm .

The longitudinal strength of these composites is given by: * σ cd = σ * V f (1 − f lc ' ) + σ m (1 − V f ) when l > lc and 2l * σ cd ' = lτ c ' V f + σ m (1 − V f ) when l < lc d where τc – smaller of either the fiber-matrix bond strength or the matrix shear yield strength. Whereas longitudinal strength is dominated by fiber strength. elastic modulus of these composites is given by: E cl = K ( E mVm + E f V f ) . a variety of factors will have a significant influence on the transverse strength. (b) Discontinuous and aligned fiber composites: Even though reinforcement efficiency is lower for discontinuous fiber composites than continuous fiber composites. If rule-of-mixtures can be applied. matrix material is softer i. Then the modulus of the composite is given by: E ct = Em E f E f Vm + E mV f = Em E f E f (1 − V f ) + E mV f Longitudinal tensile strength: as mentioned earlier. and is usually characterized by a parameter known as fiber efficiency parameter. (c) Discontinuous and randomly orientated fiber composites: Reinforcement efficiency of these fiber composites is difficult to calculate. isostress condition.e. majority of the load that was borne by fibers is now transferred to the matrix. interface bond strength. And once the fibers have fractured. σ*f – fiber tensile strength. These include properties of both the fiber and matrix. fibers strain less and fail before the matrix. discontinuous and aligned fiber composites are commercially gaining an important place. K depends on Vf and the Ef/Em ratio. Based on this criterion the following equation can be developed for longitudinal strength of the composite: * ' σ cl = σ m (1 − V f ) + σ * V f f where σ’m – stress in the matrix at fiber failure.In case of transverse loading. it is assumed that both matrix and fiber will experience the equal stress i. and the presence of voids.e. K.

bimetallics. Second Edition. Inc. Hull and T. claddings. but the composite possesses both properties. . Materials used in their fabrication include: metal sheets. high strength or light weight. 2004. Neither the filler material nor the facing material is strong or rigid. Second Edition. Sandwich structures: these consist of thin layers of a facing material joined to a light weight filler material.12. Two classes of these composites widely used are: laminar composites and sandwich structures. These layers are stacked and cemented together according to the requirement. and in aircraft for wings. fuselage and tailplane skins. woven glass fibers embedded in plastic matrix. titanium. References 1. floors. usually consists of both homogeneous and composite materials. John Wiley & Sons. etc. New York. Properties of these composites depend not only on the properties of the constituents but also on geometrical design of various structural elements. paper. Sandwich structures are found in many applications like roofs. provides a certain degree of shear rigidity along planes that are perpendicular to the faces. An Introduction to Composite Materials. Typical materials for core are: foamed polymers. synthetic rubbers. 1996. walls of buildings. steel and plywood. 3 Structural composites These are special class of composites. D. Materials Science and Engineering – An introduction. laminates. Jr. Callister. Cambridge University Press. K. Chawla. K. New York. Composite Materials Science and Engineering. 1998. Springer-Verlag. 3. thicker protective coatings. W. Examples: thin coatings. fiber-reinforced plastics. 2. William D. Clyne. Many laminar composites are designed to increase corrosion resistance while retaining low cost. inorganic cements. cotton. The core serves two functions – it separates the faces and resists deformations perpendicular to the face plane. The faces bear most of the in-plane loading and also any transverse bending stresses. Laminar composites: there are composed of two-dimensional sheets/layers that have a preferred strength direction. sixth edition. Example: corrugated cardboard. balsa wood. Typical face materials include Al-alloys.

So. which can be defined as any multiphase material that is artificially made and exhibits a significant proportion of the properties of the constituent phases. Properties of the composite can be tailored to meet the required purpose. Bangalore – 560012 India Chapter 12. composite materials are classified based on different criteria like: (1) type of matrix material – metal matrix composites. of Mechanical Engineering.Material Science Prof. How the composites are made and classified? Composites are made by combining two distinct engineering materials in most cases. Indian Institute of Science. Why do we need composites? Composites are the class of materials with special properties. and size-and-shape of dispersed phase. one is called matrix that is continuous and surrounds the other phase – dispersed phase. Composites What are composites? Why do we need composites? How the composites are made? How the presence of dispersed phase improves the properties? What are structural composites? Want to know how good you are in this chapter? What are composites? Composites are the multiphase materials. Kailas Associate Professor Dept. For ease of recognition. The constituent phases of a composite are usually of macro sized portions. How the presence of dispersed phase improves the properties? . polymer matrix composites and ceramic matrix composites (2) size-and-shape of dispersed phase – particle-reinforced composites. The properties of composites are a function of the properties of the constituent phases. fiber-reinforced composites and structural composites. Satish V. their relative amounts. it is important to have composite materials for the technologies which demand special properties. differ in form and chemical composition and essentially insoluble in each other. Millions of combinations of materials are possible and thus so number of composite materials.

Particulate composites are used with all three material types – metals.Particle-reinforced composites They are again two kinds: dispersion-strengthened and particulate-reinforced composites. carbon black enhances toughness and .e. These contain large amounts of comparatively coarse particles. mechanism of strengthening is similar to that for precipitation hardening in metals where matrix bears the major portion of an applied load. such as elastic modulus. These two classes are distinguishable based upon strengthening mechanism – dispersion-strengthened composites and particulate composites. These composites are designed to produce unusual combinations of properties rather than to improve the strength. Examples: thoria (ThO2) dispersed Ni-alloys (TD Ni-alloys) with high-temperature strength. particles are comparatively smaller. polymers and ceramics. of particulate composites achievable are in the range defined by rule of mixtures as follows: Upper bound is represented by: E c (u ) = E mVm + E pV p And lower bound is represented by: E c (l ) = Em E p E pVm + E mV p Where E and V denote elastic modulus and volume fractions respectively while c. Mechanical properties. A schematic diagram of these bounds is shown in the figure-12. matrix and particulate phases. while dispersoids hinder/impede the motion of dislocations. and are of 0. Particulate composites are other class of particle-reinforced composites. When added to vulcanized rubber.1: Schematic presentation of rule-of-mixture bounds. Here the strengthening occurs at atomic/molecular level i. Eg. and p represent composite. In dispersion-strengthened composites.1. Figure-12.: tungsten carbide (WC) or titanium carbide (TiC) embedded cobalt or nickel used to make cutting tools. SAP (sintered aluminia powder) – where aluminium matrix is dispersed with extremely small flakes of alumina (Al2O3).01-0. Cermets contain hard ceramic particles dispersed in a metallic matrix. m. Polymers are frequently reinforced with various particulate materials such as carbon black.1µm in size.

The mechanical properties of fiber-reinforced composites depend not only on the properties of the fiber but also on the degree of which an applied load is transmitted to the fibers by the matrix phase. Aluminium alloy castings containing dispersed SiC particles are widely used for automotive applications including pistons and brake applications.3. stiff but brittle fibers into a softer. which carry most off the applied load. The matrix material acts as a medium to transfer the load to the fibers. the highest strength and stiffness are obtained with continuous reinforcement. their orientation and volume fraction in addition to direction of external load application affects the mechanical properties of these composites. more ductile matrix. Length of fibers. Figure 12. Particulate reinforced composite These composites are classified as either continuous or discontinuous. which is defined as: . Generally. Discontinuous fibers are used only when manufacturing economics dictate the use of a process where the fibers must be in this form. Fiber-reinforced composites Most fiber-reinforced composites provide improved strength and other mechanical properties and strength-to-weight ratio by incorporating strong.abrasion resistance of the rubber. Particulate reinforced composite Figure 12. Effect of fiber length: Some critical length (lc) is necessary for effective strengthening and stiffening of the composite material.2. The matrix also provides protection to fibers from external loads and atmosphere.

fibers strain less and fail before the matrix. if matrix and fiber are all of equal length.lc = σ*f – ultimate/tensile strength of the fiber. the above equation transforms into E cl = E mVm + E f V f = E m (1 − V f ) + E f V f The ratio of the load carried by the fibers to that carried by the matrix is given by Ff Fm = EfVf E mVm In case of transverse loading. area fractions will be equal to volume fractions. Effect of fiber orientation and concentration: with respect to orientation.e. Am/Ac and Af/Ac are the area fractions of the matrix and fiber phases respectively. Thus. Then the modulus of the composite is given by: Em E f Em E f E ct = = E f Vm + E mV f E f (1 − V f ) + E mV f Longitudinal tensile strength: as mentioned earlier.e. Continuous fibers are normally aligned. whereas discontinuous fibers are randomly or partially orientated. matrix material is softer i. Based on this criterion the following equation can be developed for longitudinal strength of the composite: . isostrain condition. Fibers for which l >> lc (normally l >15 lc) are termed as continuous. isostress condition. τc – interface bond strength. majority of the load that was borne by fibers is now transferred to the matrix. by assuming that deformation of both matrix and fiber is the same i.e. discontinuous or short fibers on the other hand. it is assumed that both matrix and fiber will experience the equal stress i. (a) Continuous fiber composites: Under longitudinal loading. σ c = σ mVm + σ f V f When the isostrain assumption is taken into account. In the composite. d – diameter of the fiber. And once the fibers have fractured. two extremes possibilities are – parallel alignment and random alignment. Two instants of loading are: longitudinal loading and transverse loading. rule-of-mixtures results in the following: σ*d f 2τ c σc =σm Af Am +σ f Ac Ac Where.

(c) Discontinuous and randomly orientated fiber composites: Reinforcement efficiency of these fiber composites is difficult to calculate. Laminar composites: there are composed of two-dimensional sheets/layers that have a preferred strength direction. high strength or light weight. K depends on Vf and the Ef/Em ratio. (b) Discontinuous and aligned fiber composites: Even though reinforcement efficiency is lower for discontinuous fiber composites than continuous fiber composites. and is usually characterized by a parameter known as fiber efficiency parameter. discontinuous and aligned fiber composites are commercially gaining an important place. and the presence of voids. . These include properties of both the fiber and matrix. bimetallics. interface bond strength. Many laminar composites are designed to increase corrosion resistance while retaining low cost. Examples: thin coatings. woven glass fibers embedded in plastic matrix. σ*f – fiber tensile strength. Properties of these composites depend not only on the properties of the constituents but also on geometrical design of various structural elements.* ' σ cl = σ m (1 − V f ) + σ * V f f where σ’m – stress in the matrix at fiber failure. thicker protective coatings. These layers are stacked and cemented together according to the requirement. The longitudinal strength of these composites is given by: l * ' σ cd = σ * V f (1 − c ) + σ m (1 − V f ) when l > lc and f 2l lτ * ' σ cd ' = c V f + σ m (1 − V f ) when l < lc d where τc – smaller of either the fiber-matrix bond strength or the matrix shear yield strength. Materials used in their fabrication include: metal sheets. elastic modulus of these composites is given by: E cl = K ( E mVm + E f V f ) What are structural composites? Structural composites are special class of composites. K. Two classes of these composites widely used are: laminar composites and sandwich structures. claddings. Whereas longitudinal strength is dominated by fiber strength. laminates. usually consists of both homogeneous and composite materials. cotton. a variety of factors will have a significant influence on the transverse strength. If rule-of-mixtures can be applied. paper. etc.

fuselage and tailplane skins. and in aircraft for wings. Want to know how good you are in this chapter? 1. titanium. Typical materials for core are: foamed polymers. Size range of dispersoids used in dispersion strengthened composites . Usually stronger constituent of a composite is (a) Matrix Can’t define (b) Reinforcement (c) Both are of equal strength (d) 5. Usually softer constituent of a composite is (a) Matrix Can’t define (b) Reinforcement (c) Both are of equal strength (d) 4. The faces bear most of the in-plane loading and also any transverse bending stresses. balsa wood. Example: corrugated cardboard. Neither the filler material nor the facing material is strong or rigid. Typical face materials include Al-alloys. The core serves two functions – it separates the faces and resists deformations perpendicular to the face plane. Sandwich structures are found in many applications like roofs. Major load carrier in dispersion-strengthened composites (a) Matrix (b) Fiber (c) Both (d) Can’t define 3. inorganic cements. floors. Composite materials are classified based on: (a) Type of matrix None (b) Size-and-shape of reinforcement (c) Both (d) 2. but the composite possesses both properties. fiber-reinforced plastics. walls of buildings. synthetic rubbers. provides a certain degree of shear rigidity along planes that are perpendicular to the faces. steel and plywood. Last constituent to fail in fiber reinforced composites (a) Matrix define (b) Fiber (c) Both fails at same time (d) Can’t 6.Sandwich structures: these consist of thin layers of a facing material joined to a light weight filler material.

01-0. Not an example for laminar composite (a) Wood (b) Bimetallic (c) Coatings/Paints (d) Claddings Answers: 1.1 mm (d) None 7. Al-alloys for engine/automobile parts are reinforced to increase their (a) Strength (b) Wear resistance (c) Elastic modulus (d) Density 9. c a a b a . orientation.01-0.1 nm (c) 0. 2.1 µm (b) 0. 5.(a) 0. Rule-of-mixture provides _________ bounds for mechanical properties of particulate composites.01-0. and volume fraction (d) All the above 10. (a) Lower (b) Upper (c) Both (d) None 8. 4. Longitudinal strength of fiber reinforced composite is mainly influenced by (a) Fiber strength length (b) Fiber orientation (c) Fiber volume fraction (d) Fiber 11. Mechanical properties of fiber-reinforced composites depend on (a) Properties of constituents (b) Interface strength (c) Fiber length. 3. The following material can be used for filling in sandwich structures (a) Polymers (b) Cement (c) Wood (d) All 12.

c 8. d 12. a . a 7. d 10.6. a 11. b 9.

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