Presented by Iwan Susanto, Ph.

Mechanical Engineering Department

Politeknik Negeri Jakarta Created by Dr. Vika Rizkia
a cross section of
a high-
performance
snow ski, are
shown the
various
components.
(Courtesy of
Evolution Ski
Company, Salt
Lake City, Utah.)

COMPOSITE
Artificially produced multiphase
materials
they do not dissolve or merge into each other.
Design materials with properties better
than those of conventional materials
(metals, ceramics, or polymers)
A combination of two or more materials
(reinforcement, resin, filler, etc.), differing in
form or composition on a macroscale.
The constituents retain their identities, i.e..,
Normally, the components can be physically
identified and exhibit an interface between
each other.

Composite material comprises at least two chemically different

materials (heterogeneity): a reinforcement, and a matrix that
binds the reinforcement and is separated from it by a sharp
interface.
 Polymers, Metals, Ceramics.. also, continuous
1. MATRIX PHASE phase, surrounds other phase (e.g.: metal, ceramic,
or polymer)

2. REINFORCEMENT Fibers, Particles, or Flakes Also, dispersed

phase, discontinuous phase (e.g.: metal,
PHASE ceramic, or polymer)

EXAMPLES
Jello and cole slaw/mixed fruit
Peanut brittle
Straw in mud

Wood (cellulose fibers in hemicellulose and lignin)

Bones (soft protein collagen and hard apatite minerals)
Pearlite (ferrite and cementite)
 Protect phases from environment
MATRIX PHASE Transfer Stresses to phases
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

REINFORCEMENT
Enhance matrix properties
PHASE
• High strength and stiffness
Advantages of composite •
•
Low weight ratio
Material can be designed in addition
to the structure
The various geometrical and spatial characteristics of particles of the dispersed phase that
may influence the properties of composites: (a) concentration, (b) size, (c) shape, (d)
distribution, and (e) orientation
 Particle-reinforced Fiber-reinforced Structural
• Examples:
- Spheroidite matrix: particles: Adapted from Fig.

steel ferrite (a) cementite 10.19, Callister 7e. (Fig.

10.19 is copyright
(ductile) (Fe 3 C ) United States Steel
Corporation, 1971.)
(brittle)
60 mm
Adapted from Fig. 16.4,
- WC/Co matrix: particles: Callister 7e. (Fig. 16.4 is
cemented cobalt WC courtesy Carboloy
Systems, Department,
(ductile) (brittle,
carbide V m: hard)
General Electric
Company.)

5-12 vol%! 600mm

Adapted from Fig. 16.5,
Callister 7e. (Fig. 16.5 is
- Automobile matrix: particles: courtesy Goodyear Tire
tires rubber C and Rubber Company.)
(compliant) (stiffer)
0.75mm
 Particle-reinforced Fiber-reinforced Structural

The term ‘‘large’’ is used to indicate that particle–matrix interactions cannot be treated on
the atomic or molecular level

For most of these composites, the particulate phase is harder and stiffer than the matrix

The matrix transfers some of the applied stress to the particles, which bear a fraction of
the load.

The degree of reinforcement or improvement of mechanical behavior depends on strong

bonding at the matrix–particle interface

Particles can have quite a variety of geometries, but they should be of approximately the
same dimension in all directions (equiaxed). For effective reinforcement, the particles
should be small and evenly distributed throughout the matrix
 Particle-reinforced Fiber-reinforced Structural

predict that the elastic modulus should fall between an upper bound represented
by :
Rule of
mixtures
and a lower bound, or limit :

E = the elastic modulus

V = volume fraction
c, m, and p = composite, matrix, and
particulate phase

Modulus of elasticity versus volume percent tungsten for a

composite of tungsten particles dispersed within a copper matrix
 Particle-reinforced Fiber-reinforced Structural

Large-particle composites are utilized with all three material WC–Co cemented
types (metals, polymers, and ceramics) carbide. Light
areas are the
cobalt matrix;
The cermets are examples of ceramic–metal composites dark regions, the
particles of
tungsten
The most common cermet is the cemented carbide, which is carbide.100x
composed of extremely hard particles of a refractory carbide
ceramic such as tungsten carbide (WC) or titanium carbide
(TiC), embedded in a matrix of a metal such as cobalt or
nickel The spherical
reinforcing carbon
Both elastomers and plastics are frequently reinforced with black
particles in a
various particulate materials synthetic rubber
tire tread
Many of the modern rubbers would be severely restricted compound. The
without reinforcing particulate materials such as carbon areas resembling
water
black. Carbon black consists of very small and essentially marks are tiny air
spherical particles of carbon, produced by the combustion of pockets in the
natural gas or oil in an atmosphere that has only a limited air rubber.
80,000x
supply
 Particle-reinforced Fiber-reinforced Structural

Concrete is a common large-particle composite in which both matrix and dispersed phases
are ceramic materials

Concrete – gravel + sand + cement

- Why sand and gravel? Sand packs into gravel voids
Reinforced concrete - Reinforce with steel rebar or remesh
- Increases strength - even if cement matrix is cracked
Prestressed concrete - remesh under tension during setting of concrete. Tension
release puts concrete under compressive force
- Concrete much stronger under compression.
- Applied tension must exceed compressive force
 Particle-reinforced Fiber-reinforced Structural

Particles are normally much smaller, having diameters between 0.01 and 0.1 m (10 and 100
nm)

Particle–matrix interactions that lead to strengthening occur on the atomic or molecular

level

The mechanism of strengthening is similar to that for precipitation hardening. The matrix
bears the major portion of an applied load, the small dispersed particles hinder or impede
the motion of dislocations

The dispersed phase may be metallic or nonmetallic; oxide materials are often used
The dispersion strengthening effect is not as pronounced as with precipitation hardening;
however,the strengthening is retained at elevated temperatures and for extended time
periods because the dispersed particles are chosen to be unreactive with the matrix phase
 Particle-reinforced Fiber-reinforced Structural

The high-temperature strength of nickel alloys may be enhanced significantly by the

addition of about 3 vol% of thoria (ThO2) as finely dispersed particles; this material is
known as thoria-dispersed (or TD) nickel

A very thin and adherent alumina coating is caused to form on the surface of extremely
small (0.1 to 0.2 m thick) flakes of aluminum, which are dispersed within an aluminum
metal matrix; this material is termed sintered aluminum powder (SAP)
 Particle-reinforced Fiber-reinforced Structural

Carbon fibres seen under the electron microscope. Note the irregular
surface. Fibre diameters are around 5 – 7 microns (thousandths of a
mm).
 Particle-reinforced Fiber-reinforced Structural

Glass fibres being drawn from the furnace. Molten glass emerges
through a bushing – the rate of pulling determines the fibre
diameter. Because the fibres are so small, they lose heat very
quickly.
 Particle-reinforced Fiber-reinforced Structural

The surface of a fractured composite, containing both carbon and glass

fibres. Note the larger, smoother glass, and regions where fibres have
been pulled out of the plastic matrix.
 Particle-reinforced Fiber-reinforced Structural

Design goals of fiber-reinforced composites often include high strength and/or stiffness
on a weight basis.

Critical fiber length (lC) for effective stiffening & strengthening :

Ultimate (or tensile) fiber diameter

strength of fiber
fd
lc 
c shear strength of
fiber-matrix interface

For a number of glass and carbon fiber–matrix combinations, this critical length is on
the order of 1 mm, which ranges between 20 and 150 times the fiber diameter
Fibers for which l lc (normally l  15 lc) are termed continuous; discontinuous or
short fibers have lengths shorter than this .
Particle-reinforced Fiber-reinforced Structural
 Particle-reinforced Fiber-reinforced Structural

• Why? Longer fibers carry stress more efficiently!

Shorter, thicker fiber: Longer, thinner fiber:  d
f d fiber length  15 f
fiber length  15
c c
s (x) s (x)
Adapted from Fig. 16.7,
Callister 7e.

Poorer fiber efficiency Better fiber efficiency

 aligned aligned random
continuous discontinuous
 Particle-reinforced
Aligned Continuous fibers
-- Metal: g'(Ni3Al)-a(Mo)
by eutectic solidification.
matrix: a (Mo) (ductile)
2 m
fibers: g ’ (Ni3Al) (brittle)
From W. Funk and E. Blank, “Creep
deformation of Ni3Al-Mo in-situ
composites", Metall. Trans. A Vol. 19(4), pp.
987-998, 1988. Used with permission.
Fiber-reinforced Structural
-- Ceramic: Glass w/SiC fibers
formed by glass slurry
Eglass = 76 GPa; ESiC = 400 GPa.
(a) fracture
surface
From F.L. Matthews and R.L.
Rawlings, Composite Materials;
Engineering and Science, Reprint
(b)
ed., CRC Press, Boca Raton, FL,
2000. (a) Fig. 4.22, p. 145 (photo by
J. Davies); (b) Fig. 11.20, p. 349
(micrograph by H.S. Kim, P.S.
Rodgers, and R.D. Rawlings). Used
with permission of CRC
Press, Boca Raton, FL.
 Particle-reinforced Fiber-reinforced Structural

Discontinuous, random 2D fibers C fibers:

very stiff
• Example: Carbon-Carbon very strong
(b)
-- process: fiber/pitch, then C matrix:
burn out at up to 2500ºC. less stiff
-- uses: disk brakes, gas view onto plane less strong
turbine exhaust flaps, nose fibers lie
cones. in plane
(a)
 Particle-reinforced Fiber-reinforced Structural

Very thin single crystals that have extremely large length-to-

diameter ratios
1. WHISKERS They have a high degree of crystalline perfection, high strengths,
the strongest known materials

Whiskers are not utilized extensively as a reinforcement medium

because they are extremely expensive.

graphite, silicon carbide, silicon nitride, and aluminum oxide

Polycrystalline or amorphous and have small diameters

2. FIBERS Generally either polymers or ceramics
The polymer aramids, glass, carbon, boron, aluminum oxide, and SiC

Relatively large diameters

3. WIRES Steel, molybdenum, and tungsten
Particle-reinforced Fiber-reinforced Structural
 Particle-reinforced Fiber-reinforced Structural

GLASS FIBER-REINFORCED POLYMER (GFRP)

1. POLYMER COMPOSITES
MATRIX Fiberglass is simply a composite consisting of glass fibers, either continuous
or discontinuous, contained within a polymer matrix
COMPOSITE Produced in the largest quantities

Fiber diameters normally range between 3 and 20 m

It is easily drawn into high-strength fibers from the molten state

It is readily available and maybe fabricated into a glass-reinforced plastic

economically using a wide variety of composite-manufacturing techniques

As a fiber, it is relatively strong, and when embedded in a plastic matrix,

it produces a composite having a very high specific strength

They are not very stiff and do not display the rigidity that is necessary
for some applications (e.g., as structural members for airplanes and bridges)

Most fiberglass materials are limited to service temperatures below 200 C

Automotive and marine bodies, plastic pipes, storage containers, and

industrial floorings
 Particle-reinforced Fiber-reinforced Structural

CARBON FIBER-REINFORCED POLYMER (CFRP)

1. POLYMER COMPOSITES

MATRIX Carbon fibers have the highest specific modulus and specific strength of all
reinforcing fiber materials
COMPOSITE They retain their high-tensile modulus and high strength at elevated
temperatures; high-temperature oxidation, however, may be a problem

At room temperature carbon fibers are not affected by moisture or a wide

variety of solvents, acids, and bases

Exhibit a diversity of physical and mechanical characteristics, allowing

composites incorporating these fibers to have specific engineered
properties

Fiber and composite manufacturing processes have been developed that

are relatively inexpensive and cost effective

sports and recreational equipment (fishing rods, golf clubs), filament-

wound rocket motor cases, pressure vessels, and aircraft structural
components—both military and commercial, fixed wing and helicopters
(e.g., as wing, body, stabilizer, and rudder components)
 Particle-reinforced Fiber-reinforced Structural

ARAMID FIBER-REINFORCED POLYMER COMPOSITES

1. POLYMER
Known as poly paraphenylene terephthalamide
MATRIX Trade names for two of the most common are Kevlar and Nomex
COMPOSITE Longitudinal tensile strengths and tensile moduli are higher than other
polymeric fiber materials; however, they are relatively weak in compression

Known for its toughness, impact resistance, and resistance to creep and
fatigue failure

the temperature range over which they retain their high mechanical
properties is between 200 and 200 C
Chemically, they are susceptible to degradation by strong acids and bases, but
they are relatively inert in other solvents and chemicals

Since the fibers are relatively flexible and somewhat ductile, they may be
processed by most common textile operations

Ballistic products (bullet-proof vests), sporting goods, tires, ropes, missile

cases, pressure vessels, and as a replacement for asbestos in automotive
brake and clutch linings, and gaskets
 Particle-reinforced Fiber-reinforced Structural

These materials may be utilized at higher service temperatures than their base
2. METAL metal counterparts

MATRIX These materials may be utilized at higher service temperatures than their base
metal counterparts
COMPOSITE The reinforcement may improve specific stiffness, specific strength, abrasion
resistance, creep resistance, thermal conductivity, and dimensional stability

Some of the advantages of these materials over the polymermatrix composites include higher operating
temperatures, nonflammability, and greater resistance to degradation by organic fluids

The superalloys, as well as alloys of aluminum, magnesium, titanium, and copper, are employed as matrix materials

The reinforcement may be in the form of particulates, both continuous and discontinuous fibers, and whiskers.
Concentrations normally range between 10 and 60 vol%

Some of the automobile manufacturers have introduced engine components consisting of an aluminum-alloy matrix
that is reinforced with alumina and carbon fibers; Aerospace structural applications include advanced aluminum alloy
metal-matrix composites; boron fibers are used as the reinforcement for the Space Shuttle Orbiter, and continuous
graphite fibers for the Hubble Telescope
Particle-reinforced Fiber-reinforced Structural
 Particle-reinforced Fiber-reinforced Structural

3. CERAMIC Inherently resilient to oxidation and deterioration at elevated temperatures

MATRIX Specifically for components in automobile and aircraft gas turbine engines,
cutting tool inserts for machining hard metal alloys
COMPOSITE
Ceramic-matrix composites may be fabricated using hot pressing, hot isostatic
pressing, and liquid phase sintering techniques

Relatively new and expensive

Complex processing techniques

3. CARBON-
high-tensile moduli and tensile strengths that are retained to temperatures in
CARBON excess of 2000 C

COMPOSITE Low coefficients of thermal expansion and relatively high thermal

conductivities; these characteristics, coupled with high strengths, give rise to a
relatively low susceptibility to thermal shock

Low coefficients of thermal expansion and relatively high thermal

conductivities; these characteristics, coupled with high strengths, give rise to a
relatively low susceptibility to thermal shock
 Particle-reinforced Fiber-reinforced Structural

used for the manufacture of components having continuous lengths and a constant
PULTRUSION cross-sectional shape (i.e., rods, tubes, beams, etc.)

Principal reinforcements are glass, carbon, and aramid fibers, normally added in
concentrations between 40 and 70 vol%

Commonly used matrix materials include polyesters, vinyl esters, and epoxy resins

Production rates
around 1 m/min

Applications are to sporting goods (golf club shafts), vehicle drive

shafts (because of the high damping capacity), nonconductive
ladder rails for electrical service, and structural members for vehicle
and aerospace applications
 Particle-reinforced Fiber-reinforced Structural

PULTRUSION Fibers are impregnate with a prepolymer, exactly positioned with

guides, preheated, and pulled through a heated, tapering die
where curing takes place.

Emerging product is cooled and pulled by oscillating clamps

Small diameter products are wound up

Two dimensional shapes including solid rods, profiles, or hollow tubes,similar to those
produced by extrusion, are made, hence its name ‘pultrusion’
 Particle-reinforced Fiber-reinforced Structural

Prepreg is the composite industry’s term for

PREPREG continuous fiber reinforcement pre-
impregnated with a polymer resin that is
only partially cured

Prepreg is delivered in tape form to the

manufacturer who then molds and fully
cures the product without having to add
any resin

This is the composite form most widely

used for structural applications
 Particle-reinforced Fiber-reinforced Structural

Manufacturing begins by collimating a series of spool-wound continuous fiber tows

PREPREG Tows are then sandwiched and pressed between sheets of release and carrier
paper using heated rollers (calendering)

The release paper sheet has been coated with a thin film of heated resin solution to provide for its
thorough impregnation of the fibers

The final prepreg product is a thin tape consisting of continuous and aligned fibers embedded in a
partially cured resin

Prepared for packaging by winding onto a cardboard core

Typical tape thicknesses range between 0.08 and 0.25 mm

Tape widths range between 25 and 1525 mm

Resin content lies between about 35 and 45 vol%

 Particle-reinforced Fiber-reinforced Structural

FILAMENT WINDING Ex: pressure tanks

Continuous filaments wound onto mandrel

Because of the tension,

reentrant shapes cannot
be produced

CNC winding machines with several

degrees of freedom (sometimes 7)
are frequently employed

The filament (or tape, tow, or band) is either precoated with the
Void volume can be higher (3%) polymer or is drawn through a polymer bath so that it picks up
polymer on its way to the winder
Productivity is high (50 kg/h)

Applications include: fabrication of composite pipes, tanks, and pressure vessels. Carbon fiber
reinforced rocket motor cases used for Space Shuttle and other rockets are made this way
 Particle-reinforced Fiber-reinforced Structural

• Laminar Composite
Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0º/90º or 0/45/90º
-- benefit: balanced, in-plane stiffness

• Sandwich panels
Adapted from Fig.
-- low density, honeycomb core 16.16, Callister 7e.
-- benefit: light weight, large bending stiffness
face sheet
adhesive layer
honeycomb

Adapted from Fig. 16.18,

Callister 7e. (Fig. 16.18 is
from Engineered Materials
Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)
Metal (steel,
aluminium, titanium,
magnesium…)

Composite (carbon
fibre / epoxy)?
Metal (steel, aluminium, titanium, magnesium…)
Composite (carbon fibre / epoxy)?
 SEATTLE, Jan. 11, 2005 –
Boeing recently completed the first full-scale
composite one-piece fuselage section for its
new 7E7 Dreamliner program, demonstrating
concepts for 7E7 production that begins next
year. The structure, 7 m long and nearly 6 m
wide, is the 7E7's first major development
piece.

"This is a piece of aviation history," said Walt Gillette, Boeing vice president of Engineering,
Manufacturing and Partner Alignment. "Nothing like this is already in production. Hundreds
of aerospace experts from Boeing and our partners developed everything, including the
design, tools that served as the mold, programming for the composite lay-down, and tools
that moved the structure into the autoclave."

He added that using composites "allowed us to create optimized structural designs and
develop an efficient production process. We now see how all advanced airplanes will be
built from this time forward."
Metal (steel, aluminium, titanium, magnesium…)
Composite (carbon fibre / epoxy)?
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