IPE 4011

Advanced Manufacturing Process

Part A:
PRATTUSHA BHATTACHARJEE
1. Introduction to Composite
2. Metal Matrix Composite (MMC)
Lecturer (IPE Program)
3. Ceramic Matrix Composite (CMC) Department of MPE, AUST
4. Polymer Matrix Composite (PMC) 📩: prattusha.ipe@aust.edu
 Composite Materials
A materials system composed of two or more
physically distinct phases whose combination produces
aggregate properties that are different from those of their
constituents.

Composite Materials Composite Structural material + fibrous material/reinforcing agent

(Solid State)
(Matrix: the bulk form of the
composite part.
Al, Mg, Ni, Ti, Co, epoxy, high-
temperature plastic)
MMC, PMC, CMC
Continuous Phase/Primary Phase
Fiber: the raw material of suitable length
and strength.
High-strength fiber is a filament
Fibre, Particles, Flakes
Discontinuous Phase/Secondary Phase
Glass, Carbon Graphite,
Silicon Carbide, Aluminium
Oxide, Tungsten Boron
Filament
Functions of Composite Materials
Ø Fibers are embedded in the matrix, imparting strength to it.
Ø The matrix acts as an adhesive that binds the fibers together and provides solidity to the
materials
Ø The structural values of individual fibers are low, but the strength of individual fibers can
be utilized in the composite
Ø The high structural value of the matrix provides thermal stability to the fibers and protects
them from environmental stress and physical damage
Ø Reinforcing agent (fiber), strengthens the composite
Ø When Load is applied, the matrix shares the load within the secondary phase (deforming
might appear), and the stress is carried out by the reinforcing agent.
Advantages of Composite Materials
Ø High strength-to-weight or stiffness-to-weight ratio compared to individual matrix.lightweight but strong.
Ø Better fatigue properties
Ø High toughness
Ø Do not corrode like steel
Ø The fiber matrix composite reduces the potential of complete fracture
Ø High design versatility.

Disadvantages of Composite Materials

Ø Anisotropic properties – different properties in the different directions of measure. Ex. Youngs Modulus
Ø Polymerization shrinkage – polymer-based composites are subjected to chemical/solvent attack
Ø Expensive and slow manufacturing method
 Classifications of Composite Materials
Traditional Composite Synthetic Composite
(Occurs from Nature) (Components are produced separately and combined in a
controlled way to achieve desired structre, geometry and
properties)

Concrete
Mud Bricks
Plywood
Rubber Tires
Tungsten Carbide Tools

Bones Woods

Fiberglass
Structural material (Matrix)
1. Metal Matrix Composites (MMC) - mixtures of metals with ceramics, such as cemented carbides and other heat-resistant
materials.
2. Ceramic Matrix Composites (CMC) – aluminum oxide (Al2O3) or silicon carbide (SiC) embedded with fibers to improve
properties, especially in high-temperature applications
3. Polymer Matrix Composites (PMC) - thermosetting resins are widely used in PMC.
– Examples: epoxy and polyester with fiber reinforcement, and phenolic with powders.

Reinforcing Agent
• Function of reinforcing agent (secondary phase) is to reinforce the matrix materials (primary phase).
• Imbedded phase is most commonly one of the following shapes:
– Fibers
– Particles
– Flakes

Possible physical shapes of embedded phases in composite materials: (a) fiber, (b) particle, and (c) flake
1. Fibers: reinforcing agent (strength enhancement)
Circular cross-section
D = 0.0025mm – 0.13 mm

Ø Individual fibers are weaker, but a combined form of fibers is stronger than the bulk form of a matrix.
Ø Diameter Materials become oriented in the fiber axis direction Probability of defects

• Continuous fibers - very long; in theory, they offer a continuous path by which a load can be carried by the composite
parts
• Discontinuous fibers (chopped sections of continuous fibers) - short lengths (L/D = roughly 100)
– Important types of discontinuous fiber are whiskers - hair-like single crystals with diameters down to about 0.001 mm with very high
strength.
Fiber materials in fiber-reinforced composites:

• Glass – most widely used filament

• Carbon – high elastic modulus
• Boron – very high elastic modulus
• Polymers - Kevlar
• Ceramics – silicon carbide (SiC) and aluminium oxide (Al2O3).
• Metals – Steel and copper. whiskers
•• The most important commercial use of fibers is in polymer composites.
 a) One-dimensional: maximum strength and stiffness obtained in the direction of the fiber
b) Planer- reinforcement: woven fabric two dimensional
c) Discontinuous random: isotropic properties Three-dimensional
d) Discontinuous aligned: anisotropic properties

a. b. c. d.
Continuous fibers Discontinuous fibers
2. Particles: A second common shape of embedded phase is particles, ranging in size from microscopic to macroscopic.
•The distribution of particles in the composite matrix is random, and therefore strength and other properties of the composite
materials are usually isotropic
•The strengthening mechanism depends on particle size.

3. Flakes: are basically two-dimensional particles - small flat platelets

particles flakes
 The Interface
• There is always an interface between constituent phases in a composite materials.
• For the composites to operate effectively, the phases must bond where they join at the interface.

Interfaces between phases in a composite

material: (a) direct bonding between primary
and secondary phases

The Interphase
• In some cases, a third ingredient must be added to achieve bonding of primary and secondary phases.
• Called an interphase, this third ingredient can be thought of as an adhesive.

Interphase: (b) addition of a third ingredient to bond

the primary phase and secondary phase.
Properties of Composite Materials
• In selecting a composite material, an optimum combination of properties is usually required, rather than one particular
property
– Example: the fuselage and wings of an aircraft must be lightweight and strong, stiff, and tough.

• Several fiber-reinforced polymers possess this combination of properties.

– Example: natural rubber alone is relatively weak
• Adding significant amounts of carbon black to natural rubber (NR) increases its strength dramatically.

The properties of Composite Materials are Determined by three Factors:

1. The materials (matrix or reinforced materials) are used as component phases in the composite.

2. The geometric shapes of the constituents and the resulting structure of the composite system.

3. The manner in which the phases interact with one another.

 Three Types of Composite Structures
a. Laminar Composite Structure: composed of two-dimensional sheets or panels (piles or laminas) bonded to one another
and acting as an integrated piece. Shows isotopic properties.

Example: plywood in which layers are the same wood, but

grains are oriented differently to increase the overall strength of
the laminated piece
a.

b. Sandwich Structure – Foam Core: Consists of a

relatively thick core of low density foam bonded on both
faces to thin sheets of different materials. Usually made b.
from paper, polymeric foams, wood. Highly flammable. As
encapsulated with laminates, they do not get exposed to
fire. Property enhancer.

c. Sandwich Structure – Honeycomb Core: lattice of

hollow, thin walled cells with relatively high compression
and shear properties. Honeycomb achieves high strength-to-
weight and stiffness-to-weight ratios. Low density. Made of c.
resin impregnated glass fabric, aramid paper, aluminium
etc.
 Composites Applications

Aerospace – much of the structural weight of todays airplanes

and helicopters consist of advanced FRPs
 Composites Applications

Automotive –panels for cars and truck cabs

– Continued use of low-carbon sheet steel in cars is evidence of its low cost
and ease of processing
Composites Applications

Sports and recreation

– Fiberglass-reinforced plastic (FRP) has been used for
Boat hulls since the 1940s
– Fishing rods, tennis rackets, golf club shafts, helmets, skis,
bows, and arrows.