VISVESVARAYA TECHNOLOGICAL UNIVERSITY BE-

LAGAVI, 590014

SEMINAR REPORT ON

“COMPOSITE MATERIALS”
Submitted in partial fulfillment of
the requirement for the award of the
degree

Bachelor of Engineering
In

“Mechanical Engineering”
Submitted by

SHIVADARSHAN R HILLI 1MJ19ME057

Under the guidance of

Prof. KIRAN K K ASSIS-
TANT PROFESSOR
Department of Mechanical Engineering

MVJCE, Bengaluru-560067

Department of Mechanical Engineering,

MVJ College of Engineering Bangalore,
Near ITPB, Channasandra,
Bengaluru – 560067
2022-23
 An Autonomous Institute
Affiliated to Visvesvaraya Technological University, Approved by AICTE, New Delhi
Recognized by UGC under 2(F) & 12(B), Accredited by NBA & NAAC
Near ITPB, Channasandra, Bengaluru – 560067

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
Certified that the project work entitled “COMPOSITE MATERIALS” carried out by SHIV-
ADARSHAN R HILLI, 1MJ19ME057, a bonafide students of MVJ College of Engineering in
partial fulfilment for the award of Bachelor of Engineering in Mechanical Engineering of the
Visvesvaraya TechnologicalUniversity, Belagavi, during the year 2022-23. It is certified that that
all corrections/suggestions indicated for Internal Assessment have been incorporated in the report
deposited in the departmental library. The seminar report has been approved as it satisfies the aca-
demic requirements in respect of TECHNICAL SEMINAR – 19MES83 prescribed for the said
degree.

Signature of the Guide S

i
g
n
a
t
u
r
e
o
f
t
h
e
H
O
D
Prof. Kiran K K Dr.
San
thosh
N
Examiners:

Name of the examiners Sig-

na-
 ture
with
date

1. …………………………… ……………
……………
…

2. …………………………… ……………………………
 DECLARATION

We, hereby declare that TECHNICAL SEMINAR – 19MES83 entitled “COMPOSITE

MATERIALS” has been independently carried out by me under the guidance of Kiran K
K, Assistant Professor and Shiva Kumar H D Assistant Professor, Department of Mechani-
cal Engineering, MVJ College of Engineering, Bangalore, in partial fulfillment of the re-
quirements of the degree of B.E in Mechanical Engineering of Visvesvaraya Technological
University, Belagavi.

We, further declare that we have not submitted this report either in part or in full to any
other university for the award of any degree

Regards

Name-SHIVADARSHAN R

HILLI USN- 1MJ19ME057

Place: MVJCE, Bengaluru

Date:
 ACKNOWLEDGEMENT

The satisfaction and euphoria that accompany a successful completion of any task
would be incomplete without the mention of people who made it possible. So, with grati-
tude we acknowledge all those who has guided and encouraged us as beacon of light and
crowned our effort with success.
We are thankful to the Management of MVJ College of Engineering Bangalore
for their continuous support and encouragement for carrying out the TECHNICAL
SEMINAR
– 19MES84.
We are thankful to our Dr. P. Mahabaleswarappa, Principal, MVJCE, Bengaluru,
for being a constant inspiration and providing all the facilities that was needed throughout
the TECHNICAL SEMINAR – 19MES84.

We like to express our gratitude to our Dr. M. Brindha, Vice Principal, MVJCE,
Bengaluru, for constant encouragement throughout the course.
We also like to express our sincere gratitude to our Dr. M A Lourdu Antony Raj,
Registrar and Controller for Examinations, MVJCE, Bengaluru, for persistent guidance.
We are thankful to our Dr. Santhosh N, Professor and Head, Department of Me-
chanical Engineering, MVJCE, Bengaluru, for being a constant support and providing all
the facilities that was needed throughout the Technical Seminar.
We consider it as a privilege and honor to express our sincere gratitude to our guides
Krishna Prasad R, Assistant Professor and Shiva Kumar H D Assistant Professor, Depart-
ment of Mechanical Engineering, MVJCE, for his encouragement that has been a constant
source of motivation to us for successful completion of our Technical Seminar.
We are in debt to the support of all the teaching and non-teaching members of De-
partment of Mechanical Engineering, for their kind help and co-operation, throughout our
graduation. Their constant support and love have made this journey a memorable.
Finally, we wish to thank our parents for their love and encouragement, without
whom we would never have enjoyed so many opportunities.
TECHNICAL SEMINAR NUCLEAR FISSION

ABSTRACT

Composite materials are a unique class of materials that offer numer-

ous benefits over traditional materials such as metals and ceramics.
They are made by combining two or more materials, each with differ-
ent properties, to create a new material with enhanced performance
characteristics.
Composite materials are widely used in industries such as aerospace,
automotive, marine, and construction due to their high strength-to-
weight ratio, corrosion resistance, and durability.
This abstract provides an overview of composite materials, including
their history, types, advantages, and disadvantages. Additionally, the
different manufacturing processes involved in the production of com-
posite materials, such as compression molding and filament winding,
are discussed. The potential environmental impact of composite mate-
rials is also highlighted, along with the efforts being made to improve
their sustainability.
Overall, composite materials are a promising class of materials that
offer a wide range of benefits and applications, and ongoing research
and development are expected to drive further improvements and in-
novations in this field.

1
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

CONTENT

Page
No.
INTRODUCTION 3
HISTORY 4
ADVANTAGES 5
DISADVANTAGES 7
MATERIALS USED IN COMPOSITES 8
DIFFERENCE BETWEEN THERMOSETTING AND THER- 10
MOPLASTIC
COMPARISON TABLE OF VARIOUS COMPOSITE MATERI- 11
ALS
MANUFACTURING COMPOSITE MATERIALS 12
COMPRESSION MOULDING 13
FILAMENT WINDING 17
CONCLUSION 21
REFERENCES 22

2
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
 TECHNICAL SEMINAR NUCLEAR FISSION

INTRODUCTION

Composite materials are materials composed of two or more distinct

materials that, when combined, exhibit properties that are different from
those of the individual components. The resulting material is designed
to have superior strength, durability, and other properties compared to
traditional materials.

Composite materials are commonly used in a variety of applications,

such as aerospace, automotive, construction, marine, and sports equip-
ment. They are typically made up of a reinforcing material, such as fi-
breglass or carbon fibre, which is embedded in a matrix material, such
as epoxy or polyester resin.

The reinforcing material provides the composite with its strength and
stiffness, while the matrix material holds the reinforcing material in
place and transfers loads between the reinforcing fibres. Other types of
composites can include metal-matrix composites, ceramic-matrix com-
posites, and polymer-matrix composites.

Composite materials can be tailored to meet specific requirements, such

as high strength, low weight, or resistance to environmental factors such
as heat, moisture, and chemicals. They offer a number of advantages
over traditional materials, including improved performance, reduced
weight, increased durability, and lower maintenance costs. However,
composite materials can be more expensive than traditional materials,
and they require specialised manufacturing processes and techniques.

3
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

HISTORY

The history of composite materials dates back to ancient times when

humans first used natural materials like mud and straw to build struc-
tures. However, the development of modern composite materials be-
gan in the early 20th century with the discovery of synthetic polymers
and the use of fibers to reinforce materials.

Here are some key milestones in the history of composite materials:

- 1907: Leo Baekeland invented the first synthetic plastic, Bakelite,

which was used in a variety of applications, including electrical insu-
lation.

- 1930s: Glass fiber was developed as a reinforcement material for

plastics, leading to the creation of fiberglass.

- 1940s: During World War II, composite materials were used exten-
sively in military applications, such as aircraft components and boats.

- 1950s-1960s: The development of high-strength fibers, such as car-

bon fiber and aramid fiber, paved the way for the creation of high-per-
formance composites.

- 1960s-1970s: Composite materials were used in the aerospace in-

dustry, with the Boeing 747 and other aircraft incorporating com-
posites into their designs.

- 1980s-1990s: Advances in manufacturing processes, such as resin

transfer moulding and automated fibre placement, made it easier and
more cost-effective to produce composite parts.
4
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

- 2000s-present: Composite materials continue to be used in a wide

range of applications, from sports equipment and medical devices to
wind turbines and automotive components. New materials and manu-
facturing processes are constantly being developed to improve the
performance and versatility of composites.

Today, composite materials are an essential part of modern manufac-

turing, offering a range of unique properties, including high strength,
stiffness, and durability, as well as lightweight and corrosion-resistant
properties.

5
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

ADVANTAGES
1. High strength-to-weight ratio: Composite materials are much
stronger than many traditional materials like steel or aluminium,
yet much lighter, allowing for lightweight and strong structures.

2. Design flexibility: Composite materials can be designed to

have specific properties and can be folded into complex shapes,
making them ideal for creating custom parts and structures.

3. Corrosion resistance: Unlike metals, composite materials are

not susceptible to corrosion, making them ideal for use in harsh
environments.

4. Excellent electrical properties: Some composite materials are

excellent electrical insulators, making them ideal for use in elec-
trical and electronic applications.

5. Low thermal expansion: Composite materials have a low co-

efficient of thermal expansion, meaning they are less likely to
warp or distort when exposed to high temperatures.

6. Reduced maintenance requirements: Composite materials

require less maintenance than traditional materials, such as steel
or wood, which can be prone to rust, rot, and other types of dam-
age.

6
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

DISADVANTAGES

1. High cost: Composite materials are often more expensive than

traditional materials, such as steel or aluminum, due to the high
cost of the raw materials and the manufacturing process.

2. Manufacturing complexity: Composite materials require spe-

cialized equipment and skilled labor to manufacture, which can
add to the overall cost.

3. Environmental concerns: Some composite materials are not

biodegradable and can be difficult to recycle, leading to environ-
mental concerns.

4. Susceptibility to impact damage: Composite materials can be

vulnerable to impact damage, which can cause cracking and de-
lamination.

5. Susceptibility to UV damage: Some composite materials can

degrade when exposed to UV radiation, leading to discoloration
and loss of mechanical properties.

6. Flammability: Some composite materials are flammable and

can be difficult to extinguish once they catch fire.

7. Moisture absorption: Some types of composite materials can

absorb moisture, which can lead to swelling, distortion, and loss 7
of mechanical properties.
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

MATERIALS USED IN

COM- POS-
ITES

Composite materials are typically composed of two or more ma-

terials, with one of them being a reinforcement material and the

other being a matrix material. Some common

reinforcement materials used in composites include:
1. Fibres - such as carbon fibre, glass fibre, and aramid fibre.
2. Particulates - such as metal powders and ceramic particles.
3. Woven fabrics - such as carbon or glass cloth.
4. Matting - a non-woven fabric made of fibres or chopped
strands.

8
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

WOMEN FABRICS MATTING

The matrix material serves to bind the reinforcement material

together and transfer loads between the fibres or particles. Some
common matrix materials used in composites include:

1. Thermosetting resins - such as epoxy, polyester, and vinyl es-

ter

2. Thermoplastic resins - such as

nylon, polycarbonate, and polyethylene
3. Ceramic matrices - such as silicon carbide or alumina
4. Metal matrices - such as aluminium or magnesium

9
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23

EPOXIDE POLYCARBONATE
TECHNICAL SEMINAR NUCLEAR FISSION

MAGNESIUM

MATERIALS USED ALUMINA MATRICES

IN
COMPOSITES
FIBRES MATRIX FILLERS
Natural Fibres Polyethylene Nanoparticles
Ex:Hemp Ex: Silica
Ceramic Fibres Epoxy Conductive Particles
Ex: Alumina Ex: Graphite
Aramid Fibres Nylon Metal Powders
Ex: Kevlar

10
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

TABLE:1

DIFFERENCE BETWEEN THERMOSETTING AND

THERMOPLASTIC

Thermosetting Thermoplastic
Property Materials Materials
Behavior when Harden irreversibly Soften and melt
heated
Chemical reaction Undergo cross- No cross-linking
linking
Ability to reshape Cannot be
TABLE:2 Can be reshaped
reshaped multiple times
Curing process Requires heat and Does not require
pressure heat and pressure
Properties after Become infusible Remain fusible and
curing and insoluble soluble
Examples of Epoxy, phenolic, Polyethylene,
materials and polyester resins polycarbonate,
nylon, and PVC

11
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
TECHNICAL SEMINAR NUCLEAR FISSION

COMPARISON TABLE OF VARIOUS COMPOS-

ITE MATERIALS
Therm
Strength Corro
Fatigue al
Composite -to- Stiffn sion
Resista Cond
Material Weight ess Resist
nce uctivit
Ratio ance
y
Carbon
Fiber
Very Very Excell
Reinforced Very High Low
High Good ent
Plastic
(CFRP)
Glass Fiber
Reinforced Excell
High High Good Low
Plastic ent
(GFRP)
Aramid
Fiber
Excell
Reinforced High High Good Low
ent
Plastic
(AFRP)
Metal
Matrix Excellen
High High Good High
Composite t
s (MMC)
Ceramic
Matrix Very Excellen Very
High Good
Composite High t Low
s (CMC)

TABLE:3

11

DEPARTMENT OF MECHANICAL ENGINEERING 2022-23

MANUFACTURING COMPOSITE MATERIALS

 TECHNICAL SEMINAR NUCLEAR FISSION

METHODS :

Here is a list of some common methods for making composite materi-

als:

1.Compression moulding: In this method, fiber reinforcement and

resin are placed in a mold, which is then compressed under heat and
pressure to form the composite part.

2.Filament winding: In this method, continuous fibers are wound

around a rotating mandrel to create a seamless tube or other cylindrical
shape.

3. Spray-up: Similar to hand layup, spray-up involves spraying

chopped fibers and resin onto a mold or tool using a spray gun.

4. Pultrusion: This continuous process involves pulling fiber rein-

forcement through a bath of resin, then through a die to shape the com-
posite into a constant cross-section.

5. Resin transfer molding (RTM): This closed-mold process involves

injecting resin into a mold cavity containing pre-placed fiber reinforce-
ment.

6. Vacuum bagging: In this method, fiber reinforcement and resin are

placed in a mold and then covered with a vacuum bag, which is sealed
and evacuated to remove air and consolidate the laminate.

7. Prepreg layup: Prepregs are pre-impregnated fibers that are ready to

use in composite layup. Prepregs can be manually placed on a tool or
mold and then heated to cure the resin. 12

DEPARTMENT OF MECHANICAL ENGINEERING 2022-23

 TECHNICAL SEMINAR NUCLEAR FISSION

8. Injection moulding: This process involves injecting molten plastic

or other materials into a mold to create a solid part. Reinforcing fibers
can also be added to the molten material to create composite parts.

9. Hand layup: In this process, layers of fiber reinforcement and resin

are manually placed on a mold or tool, and then compressed to remove
air bubbles and excess resin.

These are just a few of the many methods used for making composite
materials. The choice of method depends on factors such as the size,
shape, and complexity of the part, as well as the desired mechanical
properties and cost of the final product.

COMPRESSION MOULDING
Compression molding is a manufacturing process used to produce com-
posite parts by compressing preheated, thermoset materials in a mold
cavity.

13
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
 TECHNICAL SEMINAR NUCLEAR FISSION

Here are the details of the compression molding process:

1. Preheating: The first step in compression molding is to preheat the

composite material in a heated mold to a specific temperature. The tem-
perature depends on the type of composite material being used and is
typically in the range of 100-200°C.

2. Loading: Once the composite material is preheated, it is placed into

the mold cavity. The amount of material used is carefully controlled to
ensure that the mold cavity is completely filled.

3. Compression: The mold is then closed, and a hydraulic press applies

pressure to the material in the mold cavity. The pressure is typically in
the range of 1000-5000 psi and is maintained for a specific time period
to allow the material to cure and solidify.

4. Cooling: After the material has been compressed and cured, the mold
is cooled to allow the material to harden and take on the desired shape.

5. Ejection: Finally, the mold is opened, and the finished part is ejected
from the mold. Any excess material is trimmed, and the part is inspected
to ensure that it meets the required specifications.

Compression molding is a popular manufacturing process used for pro-

ducing a wide range of composite parts, from small components to large
panels. It is especially useful for producing complex shapes and parts
with high strength and stiffness requirements, such as aircraft parts and
automotive components.

DEPARTMENT OF MECHANICAL ENGINEERING 2022-23 14

TECHNICAL SEMINAR NUCLEAR FISSION

Pic: Compression Moulding

Pic : Compression Moulding Box

DEPARTMENT OF MECHANICAL ENGINEERING 2022-23

15
TECHNICAL SEMINAR
Advantages and disadvantages of Compression
moulding
Advantages of Compression
Molding
Ability to produce large, complex
parts
High production rates and
efficiency
Ability to use a wide range of
materials, including
thermosetting and thermoplastic
resins
Low scrap rate and material
waste
Ability to incorporate inserts or
reinforcements into parts
Consistent, high-quality parts
Table:3
DEPARTMENT OF MECHANICAL ENGINEERING
NUCLEAR FISSION
Disadvantages of
Compression Molding
High start-up costs due to
expensive molds and machinery
Limited flexibility for changes in
design or material
Longer cycle times compared to
other molding techniques
Limited control over part
thickness and surface finish
Potential for voids or air pockets
in the finished part
Limited part size due to mold
size constraints
2022-23
16
 TECHNICAL SEMINAR NUCLEAR FISSION

FILAMENT MOULDING

Filament winding is a manufacturing process used to produce cylindri-

cal composite structures, such as pipes, tanks, and pressure vessels.
Here are the details of the filament winding process:

1. Mandrel preparation: The first step in filament winding is to prepare

a mandrel, which is a cylindrical form around which the composite ma-
terial will be wound. The mandrel is typically made of steel or alu-
minum and is coated with a release agent to prevent the composite ma-
terial from sticking.

2. Material preparation: The composite material used in filament wind-

ing is typically a fiber reinforced polymer (FRP), such as fiberglass or
DEPARTMENT
carbon OF impregnated
fiber, MECHANICAL ENGINEERING
with a thermosetting resin. The material is2022-23
prepared by passing the fibers through a resin bath or impregnation
 TECHNICAL SEMINAR NUCLEAR FISSION

system to coat them with resin.

17

3. Filament winding: The composite material is then wound around the

mandrel using a winding machine. The machine consists of a rotating
mandrel and a carriage that moves back and forth along the length of
the mandrel, laying down the composite material in a precise pattern.

4. Curing: After the composite material has been wound onto the man-
drel, it is cured to solidify the resin and create a rigid structure. Curing
is typically achieved through the application of heat, either in an oven
or through the use of infrared lamps.

5. Demolding: Once the composite structure has been cured, the man-
drel is removed from the inside of the structure. The structure is then
inspected and any excess material is trimmed off.

Filament winding is a versatile manufacturing process that can be used

to produce composite structures of varying sizes and shapes. It is com-
monly used in the aerospace, automotive, and construction industries,
as well as in the production of sporting goods and other consumer

products. The process offers several advantages over other composite

manufacturing methods,ENGINEERING
DEPARTMENT OF MECHANICAL including high strength-to-weight ratios, pre-
2022-23
cise control over fiber orientation, and the ability to produce complex
geometries.
TECHNICAL SEMINAR NUCLEAR FISSION

Pic : Filament Moulding setup

DEPARTMENT OF MECHANICAL ENGINEERING 2022-23

TECHNICAL SEMINAR
Advantages And Disadvantages Of Filament Winding
Advantages of Filament
Winding
Ability to produce high-strength,
lightweight parts
Ability to manufacture complex
shapes and contours
Low material waste and high
material utilization
Ability to incorporate continuous
fibers for enhanced strength and
stiffness
Consistent, repeatable part
quality
High production rates and
efficiency
DEPARTMENT OF MECHANICAL ENGINEERING
NUCLEAR FISSION
19
Disadvantages of Filament
Winding
High start-up costs due to
expensive equipment and tooling
Limited flexibility for changes in
design or material
Limited control over part
thickness and surface finish
Longer cycle times compared to
other molding techniques
Limited part size due to mandrel
size constraints
Difficulty in producing parts with
sharp corners or angles
2022-23
20
TECHNICAL SEMINAR NUCLEAR FISSION

CONCLUSION
In conclusion, composite materials have emerged as a vital class of
engineering materials, offering many advantages over traditional ma-
terials such as steel and aluminium. They have a wide range of appli-
cations in various industries, including aerospace, automotive, con-
struction, and sports equipment.

The ability to tailor the properties of composites by combining differ-

ent materials and production techniques has led to significant im-
provements in strength, stiffness, weight, and durability, making them
ideal for use in high-performance applications.

While composite materials have many advantages, they also have

some limitations, including higher costs, environmental concerns, and
susceptibility to certain types of damage. However, ongoing research
and development in the field of composite materials are addressing
these challenges, leading to the development of new and improved
materials that offer even greater performance and durability.

Overall, composite materials have revolutionised the way engineers

approach design and manufacturing, and their continued development
is sure to drive progress in a wide range of industries in the years to
come.

21
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23
 TECHNICAL SEMINAR NUCLEAR FISSION

REFERENCES
1. Jones, R. M. (1999). Mechanics of composite materials. CRC press.

2. Mallick, P. K. (2007). Fiber-reinforced composites: materials, manu-

facturing, and design. CRC press.

3. Gibson, R. F. (2012). Principles of composite material mechanics.

CRC press.

4. Hull, D., & Clyne, T. W. (1996). An introduction to composite mate-

rials (2nd ed.). Cambridge University Press.

5. Agarwal, B. D., & Broutman, L. J. (2009). Analysis and performance

of fiber composites (3rd ed.). John Wiley & Sons.

6. Barbero, E. J. (2010). Introduction to composite materials design (2nd

ed.). CRC press.

7. Ishai, O., & Karni, R. (2016). Mechanics of advanced materials:

Analysis of properties and performance. Elsevier.

8. Fong, Y. C., & Hsieh, T. E. (2019). Composite materials: properties,

manufacturing, and applications. Woodhead Publishing.
9. Kuczmarski, M. A., & Hitchcock, R. W. (Eds.). (2018). Composite
materials handbook-17: volume 1. CRC press.

22
DEPARTMENT OF MECHANICAL ENGINEERING 2022-23