Matrix material
Functions of the Matrix Material
(Primary Phase)
• Provides the bulk form of the part or product made of the composite
material
• 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
Matrix Materials
• Functions of the matrix
• Bind fibre togeter
• Transmit load and stresses between fibers
• arrest cracks from spreading between fibers
• do not carry most of the load
• hold fibers in proper orientation (support the overall structure)
• protect fibers from environment
• mechanical forces can cause cracks that allow environment to affect fibers
Demands on matrix
• Interlaminar shear strength
• Toughness
• Moisture/environmental resistance
• Temperature properties (matrix decides max op temp)
• Cost
Matrices - Polymeric
• Thermosets
• cure by chemical reaction
• Irreversible
• Examples
• Polyester, vinylester
• Most common, lower cost, solvent resistance
• Epoxy resins
• Superior performance, relatively costly
Matrices - Thermosets
•Polyester
Polyesters have good mechanical properties, electrical properties and chemical
resistance. Polyesters are amenable to multiple fabrication techniques and are low
cost.
•Vinyl Esters
Vinyl Esters are similar to polyester in performance. Vinyl esters have increased
resistance to corrosive environments as well as a high degree of moisture
resistance.
Matrices - Thermosets
•Epoxy
Epoxies have improved strength and stiffness properties over polyesters. Epoxies
offer excellent corrosion resistance and resistance to solvents and alkalis. Cure
cycles are usually longer than polyesters, however no by-products are produced.
Flexibility and improved performance is also achieved by the utilization of additives
and fillers.
Matrices - Thermoplastics
• Formed by heating to elevated temperature at which softening occurs
• Reversible reaction
• Can be reformed and/or repaired - not common
• Limited in temperature range to 150C
• Examples
• Polypropylene
• with nylon or glass
• can be injected-- inexpensive
• Soften layers of combined fiber and resin and place in a mold -- higher costs
Matrices - Others
• Metal Matrix Composites - higher temperature (260 – 750 C)
• e.g., Aluminum with boron or carbon fibers
• Ceramic matrix materials/carbon - very high temperature (1150 –
1400 C)
• Fiber is used to add toughness, not necessarily higher in strength and stiffness
• Glass (750 -1150 C)
Important Note
Composite properties are less than that of the fiber
because of dilution by the matrix and the need to
orient fibers in different directions.
consideration
• [Link]
• Mechanical properties
• Melting temp/decomposition temp
• Curing temp of matrix
• Viscosity
• Reactivity with fibre
• Reactivity with ambient environment (seawater)
• Cost
Model of a fiber-reinforced composite material showing direction in which elastic modulus is
being estimated by the rule of mixtures (b) Stress-strain relationships for the composite
material and its constituents. The fiber is stiff but brittle, while the matrix (commonly a
polymer) is soft but ductile.
Figure 9.3 - Fiber orientation in composite materials:
(a) one-dimensional, continuous fibers; (b) planar, continuous fibers in the form of a woven
fabric; and (c) random, discontinuous fibers
MANUFACTURING PROCESSES
OF COMPOSITES
• Composite materials have succeeded remarkably in their
relatively short history. But for continued growth, especially in
structural uses, certain obstacles must be overcome. A major
one is the tendency of designers to rely on traditional
materials such as steel and aluminum unless composites can
be produced at lower cost.
• Cost concerns have led to several changes in the composites
industry. There is a general movement toward the use of less
expensive fibers. For example, graphite and aramid fibers have
largely supplanted the more costly boron in advanced–fiber
composites. As important as savings on materials may be, the
real key to cutting composite costs lies in the area of
processing.
• The processing of fiber reinforced laminates can be divided
into two main steps:
Lay–up
Curing
• Curing is the drying and hardening (or polymerization) of the
resin matrix of a finished composite. This may be done unaided
or by applying heat and/or pressure.
• Lay–up basically is the process of arranging fiber–reinforced
layers (laminae) in a laminate and shaping the laminate to
make the part desired. (The term lay–up is also used to refer to
the laminate itself before curing.) Unless prepregs are used,
lay–up includes the actual creation of laminae by applying
resins to fiber reinforcements.
• Laminate lay–up operations fall into three main groups:
A. Winding and laying operations
B. Molding operations
C. Continuous lamination
• Continuous lamination is relatively unimportant compared
with quality parameters as not good as wrt other two
processes. In this process, layers of fabric or mat are passed
through a resin dip and brought together between
cellophane covering sheets. Laminate thickness and resin
content are controlled by squeegee rolls. The lay–up is
passed through a heat zone to cure the resin.
A. Winding Operation
The most important operation in this category is filament
winding. Fibers are passed through liquid resin, and then
wound onto a mandrel. After lay–up is completed, the
composite is cured on the mandrel. The mandrel is then
removed by melting, dissolving, breaking–out or some other
method.
B. Molding Operations
Molding operations are used in making a large number of
common composite products. There are two types of
processes:
A. Open–mold
(1) Hand lay–up
(2) Spray–up
(3) Vacuum–bag molding
(4) Pressure–bag molding
(5) Thermal expansion molding
(6) Autoclave molding
(7) Centrifugal casting
(8) Continuous pultrusion and pulforming.
1. Hand Lay-up
Hand lay–up, or contact molding, is the oldest and simplest
way of making fiberglass–resin composites. Applications are
standard wind turbine blades, boats, etc.)
2. Spray-up
In Spray–up process, chopped fibers and resins are sprayed
simultaneously into or onto the mold. Applications are lightly
loaded structural panels, e.g. caravan bodies, truck fairings,
bathtubes, small boats, etc.
3. Vacuum-Bag Molding
The vacuum–bag process was developed for making a
variety of components, including relatively large parts
with complex shapes. Applications are large cruising
boats, racecar components, etc.
4. Pressure-Bag Molding
Pressure–bag process is virtually a mirror image of
vacuum–bag molding. Applications are sonar domes,
antenna housings, aircraft fairings, etc.
5. Thermal Expansion Molding
In Thermal Expansion Molding process, prepreg layers are
wrapped around rubber blocks, and then placed in a metal
mold. As the entire assembly is heated, the rubber expands
more than the metal, putting pressure on the laminate.
Complex shapes can be made reducing the need for later
joining and fastening operations.
6. Autoclave Molding
Autoclave molding is similar to both vacuum–bag and
pressure–bag molding. Applications are lighter, faster and
more agile fighter aircraft, motor sport vehicles.
7. Centrifugal Casting
Centrifugal Casting is used to form round objects such as
pipes.
8. Continuous Pultrusion and Pulforming
Continuous pultrusion is
the composite
counterpart of metal
extrusion. Complex parts
can be made.
Pulforming is similar to pultrusion in many ways. However,
pultrusion is capable only of making straight products that
have the same volume all along their lengths. Pulformed
products, on the other hand, can be either straight or
curved, with changing shapes and volumes. A typical
pulformed product is a curved reinforced plastic car spring.
(shown in figure.)
B. Closed–mold
(1) Matched–die molding: As the name
suggests, a matched–die mold consists of
closely matched male and female dies
(shown in figure). Applications are
spacecraft parts, toys, etc.
(2) Injection molding: The injection process
begins with a thermosetting (or sometimes
thermoplastic) material outside the mold.
The plastic may contain reinforcements or
not. It is first softened by heating and/or
mechanical working with an extrusion–type
screw. It is then forced, under high pressure
from a ram or screw, into the cool mold.
Applications are auto parts, vanes, engine
cowling defrosters and aircraft radomes.
Material Forms and Manufacturing
• Objectives of material production
• assemble fibers
• impregnate resin
• shape product
• cure resin
Sheet Molding Compound (SMC)
• Chopped glass fiber added to polyester resin mixture
•Question: Is SMC isotropic or anisotropic?
Manufacturing - Filament Winding
• Highly automated
• low manufacturing costs if
high throughput
• e.g., Glass fiber pipe,
sailboard masts
Prepregs
• Prepreg and prepreg layup
• “prepreg” - partially cured mixture of fiber and resin
• Unidirectional prepreg tape with paper backing
• wound on spools
• Cut and stacked
• Curing conditions
• Typical temperature and pressure in autoclave is 120-200C, 100 psi
Manufacturing - Layups
compression
molding
vacuum bagging
Material Forms
• Textile forms
• Braiding or weaving
• Tubular braided form
• can be flattened and cut for non-tubular products
Fabric Structures
Woven: Series of Interlaced yarns at 90° to each other
Knit: Series of Interlooped Yarns
Braided: Series of Intertwined, Spiral Yarns
Nonwoven: Oriented fibers either mechanically,
chemically, or thermally bonded
Woven Fabrics
Basic woven fabrics consists of two systems of
yarns interlaced at right angles to create a
single layer with isotropic or biaxial properties.
Physical Properties
• Construction (ends & picks)
• Weight
• Thickness
• Weave Type
Components of a Woven Fabric
Basic Weave Types
Plain Weave
Basic Weave Types
Satin 5HS
Basic Weave Types
2 x 2 Twill
Basic Weave Types
Non-Crimp
Braiding
A braid consists of two sets of yarns, which are helically
intertwined.
The resulting structure is oriented to the longitudinal axis
of the braid.
This structure is imparted with a high level of
conformability, relative low cost and ease of manufacture.
Braid Structure
Types of Braids
Triaxial Yarns
A system of longitudinal yarns can be introduced
which are held in place by the braiding yarns
These yarns will add dimensional stability, improve
tensile properties, stiffness and compressive strength.
Yarns can also be added to the core of the braid to
form a solid braid.
Fabric effects on material properties
Resin transfer molding (RTM)
• Dry-fiber preform placed in a closed mold, resin injected into mold,
then cured
Material Forms
• Pultrusion
• Fiber and matrix are pulled through a die, like extrusion of
metals -- assembles fibers, impregnates the resin, shapes
the product, and cures the resin in one step.
• Example. Fishing rods
Pultrusion
Manufacturing
• Tube rolling - tubular products
• Examples
• fishing rods
• golf clubs
• oars
• Prepreg tape typically used wrapped in 2 directions or
spiral wrapped
