Advanced Composites

DE ZG 526

BITS Pilani Shashank Tiwari

Pilani Campus
 BITS Pilani
Pilani Campus

Advanced Composites
Lecture 1
About the Course:

• 5 Credit course
• 32 hours of online lectures (2 hours/week)
• 32 hours of assignments/case study/tutorials
• 64 hours of self learning from student
• E-learning Portal : https://elearn.bits-pilani.ac.in
• Announcements
• Quizzes and assignments
• Study material

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 Course Objective

▪ The Course is for higher degree students and intended to focus

their attention to the mechanics of different composite materials.

▪ Composite Materials and their classifications. Properties of

different matrix (polymer, metal and carbon) and fiber (glass,
carbon, aramid) materials. Composites used in aerospace,
automobiles and manufacturing industries.

▪ Manufacturing processes for composites Materials.

▪ Analysis of unidirectional and layered composites..

▪ Testing of Composite Materials and Emerging Composite

Materials.

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Text books:
B.D. Agrawal L.J. Broutman and K. Chandrashekhara “Analysis and
Performance of Fiber Composites”, John Wiley and Sons Inc,.

Reference book:
▪ R J Crawford, “Plastics Engineering”, Butterworth Heinemann, Elsevier

▪ Krishan K. Chawla, “Composite Materials: Science and Engineering”,

Second edition. Springer-Verlag, Newyork, 2010.

▪ Brigante, Domenico, New Composite Materials, Selection, Design, and

Application, Springer., 2014.

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Evaluation Scheme:

Evaluation Name Type Weight Duration Schedule

Component

EC - 1 Assignments/ Individual 10% 2 Weeks February 1-15, 2020

Quiz and Take-
home
Lab Online 20% - Lab Calendar will be
uploaded in your
course page
EC - 2 Mid-Semester Closed 30% 2 Hrs Sunday, 08/03/2020
Examination Book (AN)
2 PM – 4 PM
EC - 3 End- Open Book 40% 3 Hrs Sunday, 03/05/2020
Semester (AN)
Examination 2 PM – 5 PM

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Course Content:

• Introduction to Composites
• Necessity of Composites
• Classification and characteristics of composites
• Applications of composites
• Classification and Properties of matrix and fiber materials
• Fabrication of Composites
• Behavior of Unidirectional Composites
• Damage and failure of composites
• Analysis of Laminated Composites
• Performance of Fiber composites
• Emerging trends in Composites
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Introduction to Composites:

What is composite?
Definition:
➢ A material composed of two or more distinct constituent
materials or phases.
➢ Constituents that are combined at a macroscopic level and
are not soluble in each other.
➢ Constituent phases have significantly different physical
properties, and thus the composite properties are
noticeably different from the constituent properties.

A composite is considered to be any multiphase material that

exhibits a significant proportion of the properties of both
constituent phases such that a better combination of properties is
realized.

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Introduction to Composites:

Classification of certain materials as a composite:

1. Combination of materials should result in significant
property changes
2. Content of the constituents is generally more than 10 %
3. In general, property of one constituent is much greater
( ≥ 5) than the other

One constituent is called the reinforcing phase and the one in which it is
embedded is called the matrix.
The reinforcing phase material may be in the form of fibers, particles, or
flakes. The matrix phase materials are generally continuous.

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Examples of Composites:

❑ Flesh in the human body reinforced with bones,

❑ concrete reinforced with steel
❑ epoxy reinforced with graphite fibers, etc.

Image ref: learn.captain.com/

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Example: Naturally Found Composites:

wood, where the lignin matrix is reinforced with cellulose fibers

Image ref: rcs.org, Green Chem., 2013, 15, 550-583

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Example: Naturally Found Composites:

Bones in which the bone-salt plates made of calcium and phosphate ions reinforce
soft protein collagen.

Image ref: https://diffzi.com/

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Example: Man Made Composites:

Ceramic Matrix Composites Glass Fiber Composite

http://www.arlinfratech.com/
http://www.ceramicsexpousa.com

Windshield

Carbon Fiber Composite

https://www.goodaero.com
https://www.on-timeautoglass.com/

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History of Composites:

4000 B.C. – laminated writing material from the papyrus plant

3400 B.C. – Egyptians and Mesopotamian used straw bricks
3000 B.C. – Composite Bow (Angara Dating)

Materials Used:
Wood, Horn, Sinew (Tendon), Leather, Bamboo and Antler (Deer
horn)

Source: http://compositeslab.com/,

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History of Composites:

Horn and Antler: naturally flexible and

resilient
Sinews: back tendons or hamstrings of
cows and deer
Glue: From bladder of fish
Strings: Sinew, Horse hair, Silk

Source: http://medieval2.heavengames.com

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History of Composites:

❑ The first synthetic (man-made) resin was developed between 1870 and
1890.
❑ Modern era of composites ushered in 1907 with creation of Bakelite, one of
the first synthetic resins.
❑ Unsaturated polyester resins were patented in 1936.
❑ By the late 1930s, other high-performance resin systems had become
available, including epoxy resins.
❑ Owens-Illinois Glass Company developed a process for drawing glass into thin
strands or fibers and began weaving them into a textile fabric.
❑ In 1942, engineer Ray Greene of Toledo, Ohio (who had worked for the
Owens-Illinois Glass Company) made a dinghy from fiberglass and polyester
resin.

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 History of Composites:

❑ During and after World War II, tremendous usage in military application.

❑ Fiberglass pipe in the oil industry in 1948 for corrosion resistance.

❑ Rapid growth through the 1950s: Boats, trucks, sports cars, storage tanks, pipes,
ducts and many other products were built using composites.

❑ 1950s advanced manufacturing methods: Pultrusion, vacuum bag molding, and

large-scale filament winding.

❑In 1953, the 1st production Chevrolet Corvette with fiberglass body panels rolled
off the assembly line.

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History of Composites:

The 1953 Chevrolet Corvette, one of

the first mass-produced cars to have a
body made from composite materials

Fighter/Bomber during World War II

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History of Composites:

❑ Carbon fiber: Aerospace, automotive, marine and consumer goods (1961).

❑ Kevlar, a para-aramid fiber: ballistic and stab-resistant body armor (1966).

❑ 1970s, the automotive market surpassed marine as the number one composites
market.

❑ During the late 1970’s and early 1980’s, composites were first used in
infrastructure applications.

❑ Significant usage in aerospace industry.

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Introduction to Composites:

What are advanced composites?

These composites have high performance reinforcements of a thin
diameter in a matrix material such as epoxy and aluminum.
Examples are graphite/epoxy, Kevlar/epoxy, and boron/aluminum
composites, Nano composites.
These materials have now found applications in commercial
industries as well.

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Application of Composites:

Aerospace

All-Composite Cryogenic Tank by NASA

Source: http://compositeslab.com/

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Application of Composites:

Aerospace

LCA aircraft, more than 40% of the

structural weight of the aircraft is
built in advanced composite
materials
India's Advanced Light Helicopter (ALH)
extent of composites used in the structure
is about 60% by wetted area (29% by
weight)

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Application of Composites:

Automotive

BMW i3 electric car

Chevrolet Silverado
CFRP replacements for the bumpers,
tailgate and inner cargo box
Source: http://compositeslab.com/

https://www.materialstoday.com

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Application of Composites:

Transportation

Walmart uses CFRP for the truck’s panels

Source: http://compositeslab.com/

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Application of Composites:

Architecture
Infoshop Made from FRP at the new bus transit
center at Union Station in Washington, D.C

A super structure
hanging garden in
Birmingham

Amsterdam’s Stedelijk Museum

Aramid and carbon fiber made Entrance Extension

Source: http://compositeslab.com/

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Application of Composites:

Energy https://www.nanalyze.com

Wind Turbine

Solar panel

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Application of Composites:

Infrastructure

GFRP utility crossarms

A lifting bridge is made from

lightweight composites

Pedestrian Bridge, Wolf Trap National Park

Source: http://compositeslab.com/

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Application of Composites:

Marine

Boston Whaler Boat Military ships

CRPF lightweight yacht

Source: http://compositeslab.com/

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Application of Composites:

Sports and Recreation

Foldable Boat with Fiberglass

Source: http://compositeslab.com/

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Why Composites:

Enhanced desired properties!

Monolithic metals and their alloys cannot always meet the demands of
today’s advanced technologies. Only by combining several materials
can one meet the performance requirements

• Strength
• Stiffness
• Toughness
• Corrosion resistance
• Wear resistance
• Reduced weight
• Dimensional Stability
• Fatigue life
• Thermal/Electrical insulation and conductivity
• Acoustic insulation
•Tailorable properties
Most composites have been created to improve combinations of mechanical characteristics

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Why Composites:

Mechanical Advantage of composite

For example, the strength of a composite could be the same as steel,

but the specific strength may be three times that of steel.
What does this mean to a designer?

Take the simple case of a rod designed to take a fixed axial load.
The rod cross section of composite would be same as that of the steel,
but the mass of composite rod would be one third of the steel rod

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Introduction to Composites:

Specific Modulus and Specific Strength of Typical Fibers, Composites, and Bulk Metals

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Challenges with Composites:

➢ High cost of raw materials and fabrication

➢ Composites are brittle and thus are more easily damageable.
➢ Transverse properties may be weak.
➢ Matrix is weak, therefore, low toughness.
➢ Reuse and disposal may be difficult.
➢ Formability and Joining is difficult
➢ Repair introduces new problems

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Classification of Composites
Most composites have been created to improve combinations of mechanical
characteristics such as stiffness, toughness, and ambient and high-temperature strength.

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