Composite Material Construction

1.1 i) In a composite material, Matrix refers to the resin material which combines and

holds the fibre together. Matrix is the component which gives shape size to the

composite material. Matrix is the material which distributes the load among the

fibres. In the example given in the question, the function of the matrix is done by

the concrete as it holds the rods together and it gives the overall shape and

structure. Thus, the matrix phase is concrete.

ii) In the example given, Steel rods are the component which takes the external

tensile load. Thus, the Steel rods can be regarded as the fibre phase.

iii) When several layers of lamina are bonded together it is called laminate. Since

the number of layers in the above example in the question is only one, the structure

should be termed as lamina.

1.2 By comparing graphite epoxy composite with steel, we can see that composites

can offer:

(i) Higher ultimate tensile strength

(ii) Lower coefficient of thermal expansion

(iii) Much lighter weight and

(iv) Comparable Young's modulus.

All these makes composites advantages over simple homogeneous monolithic

materials.

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1.3 The three systems used to classify a composite material are;

i. Fibre reinforced composite – it is a composite in building material that

consist of three components;

• The fibre as the discontinuous or disposed phase

• The matrix as the continuous phase

• The fibre inter phase region, also known as the interface.

ii. Particular composite – a particle has no long dimension particle composite

consist of particles of one material dispersed in a matrix of a second

material. Particles may have any shape or size but are generally spherical,

ellipsoidal, polyhedral or irregular in shape. They may be added to a liquid

matrix that later solidifies grown in place by a reaction such as age

hardening.

iii. Laminated composite – a composite laminate is an assembly of layers of

fibrous composite material which can be joined to provide required

engineering properties, including in plane stiffness, bonding stiffness,

strength and co-efficient of thermal expansion.

1.4 i) Three advantages for using graphite as a fibre;

• it has a negative coefficient of thermal expansion

• Can be used for high precision and thermal stable applications.

• High specific stiffness and high specific strength.

ii) Three advantages for using epoxy as a matrix;

• Good adhesion to all types of fibres

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 • High corrosion resistance compared to polymer matrices

• Wide range of mechanical properties like easy processing. Low shrinkage.

iii) Major steps on manufacture of graphite fibers from polyacrylonitrile (PAN)

• PAN precursor material is initially spun into fibre form

• These precursor are then stretched through application of tensile load

• During stretching, they are also subjected to high temperatures (200°C –

300°C) for 24 hours in an oxidising atmosphere. This process is called

stabilisation.

• These stabilised fibres are next subjected to pyrolysis at 1500°C in inert

atmosphere. This process is called carbonisation. During this process, most

of non-carbon element are driven out of PAN fibres.

• Next, these fibres are “graphitised” by heating them at 3000°C in inert

environment. This improves tensile modulus of fibres as graphite crystals

develop in carbon.

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1.5 Manufacture of curved profile pipe using hand-layup with prepreg tape using a

split-mould.

2.1 i) Void of a composite parts is a bore that remains unfilled and typically the result

of poor manufacturing of material and are deemed undesirable. It affect the

mechanical properties and lifespan of composite parts of material. A resin with a high

viscosity will likely produce voids in composite.

ii) The factors that influence the quantity and location of voids are; pre-peg

impregnation, surface morphology, casing parameters, compaction pressures. Fibre

bridging excessive resin bleed and thickness layup.

iii) The vacuum bagging system combined with autoclave is a common method used

in industrial processes to achieve a low void contact for thermoset composite. Vacuum

evacuation is the way of reducing exciting amount of voids by physically transporting

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the voids out of the resin and fibre network through vacuum line and it is influenced by

the viscosity of resin. Autoclave pressure is pressure used to assist vacuum in

removing trapped air and excess resin while at the same time preventing volatiles from

coming out of the resin at high temperatures.

2.2 Thinner fibres are stronger because;

• the thinner fibres have lesser concentration of defects (both internal and surface

defects (surface flaws), defects and flaws are the site of stress concentration,

if the flaws are less the stress concentration sites in the fibre will be less and

hence the fibre will be stronger.

• if the internal defects are less, then the number of dislocations also would be

less.

• The thinner fibres have aligned crystal structures along the natural axis of fibre.

2.3 i) Tapered tube can be manufactured using the filament winding process. This

process involves continuous strands of dry fibres are:

a. Impregnated with the resin of epoxy.

b. Wound into the mandrel via a CNC control at the precise angles.

c. Pressure is applied externally for the compaction

d. Heat is then cured to solidify.

After that the composite solid which is formed is then extracted from the mandrel

to form the tube.

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References

1. https://www.youtube.com/watch?v=bBbOUDDJv4Q

2. Kaw, A.K., Mechanics of Composite Materials, CRC Press, 1997.

3. EMT3701-SG01-70676674-2021 Study Guide, UNISA