Composite

Materials
 Why Composite
Modern technologies require materials which have
unusual combinations of properties that can not be
provided by any single material.
For example, aircraft engineers would like to have
structural materials having low density,
stiffness(resists deformation), high strength,
impact resistant and which are not easily corroded.
All these properties can not be met with any single
material, because strength is associated with high
density and increase in stiffness would mean
decrease impact strength
That is why the concept of composite materials
comes into play.
Practically everything in this world is a composite material.

For example,

wood is a fibrous composite made up of strong and flexible

cellulose fibres in a stiffer lignin matrix.

Bone is a composite made up of short and soft collagen

fibres embedded in a hard and brittle mineral matrix called
apatite.
A composite material is the material which meets
the following conditions

(i) It is prepared artificially

(ii) It consists of two or more physically or

chemically distinct phases, which are separated by
a distinct interface.

(iii) The constituents retain their identities and are

immiscible
 COMPOSITE MATERIALS
Definition of Compsites
Composites are engineered
materials(also called composition
materials) made from two or more
constituent materials with significantly
different physical or chemical
properties and which remain separate
and distinct on a macroscopic level
within the finished structure.
CONSTITUENTS OF COMPOSITES

Composite materials generally comprise of just two

phases

(i) The constituent forming the body of the

composite, called the 'matrix'

(ii) The structural constituent called 'dispersed

phase' or the reinforcing material.

The properties of the composites are determined by

the properties of the constituent phases, their
relative amounts and their distribution and
orientation.
Matrix Phase

The matrix phase of composites has several important

functions like-
• It binds the reinforcing material (dispersed phase)
together,

• protects the reinforcing material from surface damage

due to mechanical abrasion or chemical reaction.

• It separates the individual particles of the reinforcing

materials

It acts as a medium by which external load is

transmitted and distributed to dispersed phase.
Constituents of Composites

Matrix Phase
➢ Continuous body constituent

➢ Provides bulk form

➢ May be a metal, polymer or ceramic

Materials used as matrix
include-polymers, metals and ceramic.
Thus we have

• Polymer matrix composites (PMC)

• Metal matrix composites (MMC)

• Ceramic matrix composites (CMC)

ii) The Dispersed Phase (reinforcement)
To improve the strength of a matrix, the reinforcement must be stronger
and stiffer than that of the matrix.

Properties of the composites, to a large extent, depend

upon the properties: the reinforcing materials, their
geometry, which is described by shape, size and size
distribution and orientation

They are chosen for their high strength and modulus.

The most effective reinforcements are long fibres, and the

composites so formed are called fibre reinforced
composites.
Constituents of Composites
Dispersed Phase/Reinforcement
➢ Structural constituent

➢ Determines internal structure

➢ May be fibres, particles, flakes and whiskers

 MATRIX RULE
The matrix material surrounds and supports the
reinforcement materials by maintaining their relative positions.
The matrix material largely determines the
processing method.

Reinforcement Rule
The reinforcements impart their special
mechanical and physical properties to enhance
the matrix properties.
 THE FINAL RESULT
If the composite is designed and
fabricated correctly, it combines the
strength of the reinforcement with the
toughness of the matrix to achieve a
combination of desirable properties
not available in any single
conventional material.
 FOR EXAMPLE
polymer/ceramic composites have
a higher modulus than the
polymer component,
but are not as brittle as ceramics.
CONSIDERATIONS FOR SELECTING THE
REINFORCEMENTS & MATRIX

There are certain considerations for

selecting the reinforcements and the matrix
such as:
melting point, volatility (instability), density,
elastic modulus, coefficient of thermal
expansion, strength, creep characteristics,
fracture toughness & compatibility between
fiber & matrix.
 COMPATIBILITY

The last consideration of compatibility

is divided into three categories,
namely:
chemical compatibility,
thermal compatibility &
compatibility with the environment
Classification of Composites
 Organic/Polymer Matrix Composites (PMCs)
➢ Thermosets have well bonded 3-D
molecular structure after curing
➢ Decompose instead of melting on
hardening
➢ Thermoplastics have 1/2-D molecular structure
➢ Show exaggerated M.pt
➢ Process of softening at elevated temp can be reversed to regain its properties
during cooling
 Metal Matrix Composites (MMCs)
➢ High Strength, fracture toughness and stiffness
➢ Withstand elevated temp in corrosive environment than polymers
➢ Used in engineering applications where the operating temp lies b/w 250°C to
750°C
➢ Steel, Al, Ti, Cu, Mg, super alloys

Ceramic Matrix Composites (CMCs)

➢ Solid materials exhibiting strong ionic bonding in general and in few cases
covalent bonding
➢ High M.pt, good corrosion resistant, stability at elevated temp and high
compressive strength
➢ Used in engineering applications where the operating temp lies b/w 800°C to
1650°C
Carbon/Carbon Matrix Composites

➢C/Cs are developed specifically for parts that must

operate in extreme temp ranges
➢Composed of a carbon matrix reinforced with C yarn
fabric, 3-D woven fabric, 3-D braiding etc
➢Applications ranging from rockets to aerospace
➢Extremely high temp resistance (1930°C-2760°C)
➢Good resistance to thermal shock
Classification of Composites
Based on Reinforcement
Fibre Reinforced Composites
➢ Long thin filaments of polymer, metal or ceramic possessing high length-
to diameter ratio and high tensile strength

➢ Glass fibres
➢ Carbon fibres
➢ Aramid fibres
Particulate Reinforced Composites
➢ Small coarse metallic/non-metallic powders (carbon black, carbides,
silica, mica) mixed with polymeric matrix
➢ Due to addition of these particles, the surface is rendered good hardness
even at higher operating temp
➢ Good electrical and thermal conductivities
 Laminar Composites
➢ Several layers of two or more metal materials are placed alternatively in a
determined order
➢ Can be prepared using powder metallurgy techniques
➢ Properties depend on every constituent material and on their assembled
geometrical design
➢ Metal cladded materials, bimetallics, protective coatings, laminates
 Sandwich Composites
➢ Made of two thin layers called faces joined to an intervening layer called core
between them
➢ Faces can be made from various materials such as fibre-reinforced plastics,
aluminium alloys, titanium, steel
➢ Faces bear most in-plane loading and transverse bending stresses

➢ Core could be cement, rubber, balsa wood, formed polymers etc

➢ Core separates the faces of the sandwich panel assembly and tends to resist
deformations perpendicular to the face
Example, in 1986 air Craft voyager
completed non stop flight
around the world without refuelling
because of the use of sandwich
composite in its manufacture,
resulting in lower weight and
hence, fuel saving.
 Flake Composites
➢ These are solid materials added in to the composite materials
➢ Mica flakes are added to render hardness
Properties of Composites
Advantages of Composites

➢ Strength-to-weight and stiffness-to-weight are greater than

steel or Al
➢ Fatigue properties are better than common engineering
materials
➢ Cannot corrode like steel
➢ Ease of fabrication of large complex structural shapes or
modules-modular construction
➢ Ability to incorporate sensors in the material too monitor and
correct its performance
 Factors affecting properties of Composites
The properties depend upon
➢ Relative amounts of constituents (Concentration)
➢ Distribution and orientation of the constituents
➢ Shape and size of the constituents
 STRENGTH OF COMPOSITES
The strength of the composite depends primarily on the
amount, arrangement and type of fiber (or particle)
reinforcement in the resin.

Typically, the higher the reinforcement content,

the greater the strength.
In some cases, glass fibers are combined
with other fibers, such as carbon or aramid
composite that combines the properties of
more than one reinforcing material.
 THE RULE OF PARTICLES
Particles are used to

Increase the modulus of the matrix,

To decrease the ductility of the matrix.

Particles are also used to produce

inexpensive composites.
 EXAMPLE OF PARTICLE COMPOSITE

An example of particle reinforced

composites is
car tire
which has carbon particles in a matrix
of the elastomeric polymer poly-iso-
butylene.
Cermet is another important particle reinforced
composite

which is composed of extremely hard particles of a

refractory carbide, such as tungsten carbide or
titanium carbide, embedded in a matrix of metal
such as cobalt or nickel.

These composites are utilized extensively

as cutting tools for hardened steels.

No single material could possibly provide the

combination of properties possessed by a cermet.
 ANOTHER EXAMPLE

Another example for particle-reinforced

composite is concrete where the
aggregates ( sand & gravel) are the
particles and cement is the matrix. PRCs
support higher tensile, compressive and
shear stresses.
 ADVANTAGES OF CERAMIC FIBERS

Continuous ceramic fibers are very good for

reinforcing ceramic materials. They combine
rather high strength and elastic modulus with
high temperature capability and a general
freedom from environmental attacks,
making them attractive as reinforcements in
high temp. applications
LIMITATION OF USING FIBER REINFORCEMENT

Fibers are difficult to process into

composites which makes fiber-reinforced
composites relatively expensive.
EFFECT OF FIBER PARAMETERS ON
COMPOSITE PROPERTIES

The arrangement or orientation of the

fibers relative to one another, the fiber
concentration, and the distribution all
have a significant influence on the
strength and other properties of fiber-
reinforced composites.
WHERE TO USE DISCONTINUOUS FIBERS

Applications involving totally

multidirectional applied stresses
normally use discontinuous fibers,
which are randomly oriented in the
matrix material.
SHORT FIBERS ADVANTAGES

Production rates for short-fiber

composites (both aligned and
randomly oriented) are rapid, and
complicated shapes can be formed
which are not possible with continuous
fiber reinforcement.
In sports goods industry the items where carbon fiber
reinforced resin are used are archery bows, fishing
rods, tennis rackets, cricket balls etc.

Blades in turbines, compressors, windmills, flywheels

have been made of carbon fiber.

• Other application of carbon fiber composites include

cargo shipping containers for rail, sea and land
transportation.

A few companies are making musical instruments

such as guitars, violins out of carbon fiber reinforced
composites.
Applications of Composites

Transportation: Manufacturing of
automobile parts, racing vehicle
components and engine parts

Marine: Used as propeller

shafts, hulls, spars (for racing
boats) etc
Aerospace: Used in military aircrafts, helicopters, missiles and rocket
components etc

Consumer product: Used in sporting goods tennis rackets and in musical

instruments
Electronics and Communication: Used in industrial and scientific equipments like
high speed machinery, electronic circuit boards (PCB), antenna etc

Safety Equipment's: Ballistic protection and air bags of cars etc

Bio-medical Applications: Used as artificial heart valves, knee replacement caps,
dentistry etc

Composite Applications in Buildings and Construction

 Limitations of Composites
➢High cost of raw materials and fabrication
➢Reuse and disposal may be difficult
➢Difficult to attach
➢Difficulty with analysis