QUESTION ONE

(a) Discuss with specific examples the difference between composite and alloy (5marks)

(b) Composite materials typically comprise of matrices and reinforcement materials. In what ways(s) are
the rules of both constituents different? (5 marks)

(c) Mention three (3) typical metal matrix composites (MMC) types and two(2) applications each. (5
mark)

(d) A frustum-like combustion chamber fabricated using powder metallurgy toute is repemented below.
The chamber is made of a high entropy alloy Aly Co Crufe Ni reinforced with 10% Sic. The upper (R) and
lower (IR) diameters of the fabricated composte are 0.5 m and 0.8 in respectively. If the bright this 1.2
m. calculate the mass of Al, Co, Cr, Fe, Ni and Sic powders that will I be required to produce the
composite of Al-2.7 plem'; p of Co-E9 g/cm3; p of Cr-7.14 g/cm³, pof Fe-7.8 g/m²; p of Ni-8.9 giem; p of
SiC-501 gm) (13) marks)

QUESTION TWO

Briefly discuss with appropriate diagrams any four of the composite manufacturing procedures listed
below. For each of the techniques; comment on their materials options, application, and advantages. (6
marks each)

(a) Filament winding

(b) Resin Transfer Moulding

(c) Wet/Hand layup

(d) Spray Lay-up

(e) Pultrusion

(f) Vacuum Bagging

QUESTION THREE

(a) What is the importance of composite characterization? Mention 3 types of composite

characterization techniques and their applications. (6 marks)

(b) Describe the various steps that you would carry out in sccessing a composite's microstructurs. (6
marks)
(c) Alumina fibres are commonly used as reinforcement materials, triefly describe some of their
properties and applications. (6 marks)

(d) Depending on the type of composite, the reinforcements in fibre reinforced composites may be
natural or advanced. (i) Give three examples for each category, (ii) Briefly describe the properties of any
two in (i) (6marks)

QUESTION FOUR

(a) Discus the benefits of employing polymer composite materials (PMC). Provide several instances of
applications where PMCs have been successfully employed, and then explain why those applications
employed PMCA (10 marks)

(d) A continous and aligned glass fiber-reinforced PMC consists of 30 vols of glass fibers having a
modulus of elasticity of 60 GP's and 70 vol% of a polyester resin that, when hardened, displays a
modulus of 3.4 GP Compute De modulus of elasticity of this composite in the longitudinal direction. (ii) If
the cross-sectional area is 350 min and a stress of 70 MPa is applied in this longitudinal direction,
compute the magnitude of the load carried by much of the fiber and matrix phases. (iii) Determine the
strain that is sustained by each phase when the stress in part b is applied. (14 marks)

QUESTION FIVE

(a) List four reasons why glass fibers are most used for reinforcement. (4 marks)

(b) Why is the surface perfection of glass fibers so important and what measures are taken to protect
the surface of glass fibers? (6 marks)

(c) Ceramic-Matrix Camposites (CMC) are known for significantly high fracture toughness at extremely
high temperature applications (e.g., heat exchanger tube and thermal protection system). Explain the
different types of toughening mechanisms in CMC. (8 marks)

(d)Discuss the effect of particulate and fibre reinforcement on mechanical properties of composites
materials. Briefly describe the strengthening mechanism responsible for the mechanical properties. (6
marks)
### QUESTION ONE

#### (a) Difference Between Composite and Alloy

**Composite:**

- *Definition:* A composite is a material formed by combining two or more distinct constituents, each
retaining its identity and properties.

- *Examples:* Fiber-reinforced composites like Carbon Fiber Reinforced Polymers (CFRP) used in
aerospace for high strength-to-weight ratio.

**Alloy:**

- *Definition:* An alloy is a mixture of two or more elements, at least one being a metal, creating a new
material with improved properties.

- *Examples:* Bronze (copper-tin alloy) and Stainless Steel (iron-chromium-nickel alloy).

**Difference:**

1. *Composition:* Composites maintain the identity of individual materials, while alloys create a
homogeneous material.

2. *Properties:* Composites exhibit a combination of properties from constituents. Alloys often possess
unique properties not found in individual elements.

#### (b) Rules of Constituents in Composites

**Matrix:**

- *Role:* The matrix binds and supports the reinforcement, transferring loads.

- *Characteristic:* Generally, the matrix is a softer and less stiff material compared to the
reinforcement.
**Reinforcement:**

- *Role:* Reinforcement enhances strength, stiffness, and other specific properties.

- *Characteristic:* The reinforcement is typically stronger and stiffer than the matrix.

#### (c) Metal Matrix Composites (MMC) and Applications

1. **Aluminum Matrix Composite (Al/SiC):**

- *Application:* Used in automotive components for its lightweight and enhanced strength.

- *Benefits:* Improved thermal conductivity and wear resistance.

2. **Titanium Matrix Composite (Ti/SiC):**

- *Application:* Aerospace components for its high-temperature resistance.

- *Benefits:* Enhanced strength and toughness.

3. **Magnesium Matrix Composite (Mg/Alumina):**

- *Application:* Structural components in aerospace and automotive industries.

- *Benefits:* High strength-to-weight ratio and corrosion resistance.

#### (d) Calculation of Powder Mass for Combustion Chamber

Given the densities (p) and dimensions, calculate the volumes of Al, Co, Cr, Fe, Ni, and SiC using the
formula \(V = \frac{m}{\rho}\), then find the mass using the relationship \(m = \rho \times V\).

### QUESTION TWO

#### Composite Manufacturing Procedures

**(a) Filament Winding:**

- *Materials:* Suitable for thermosetting and thermoplastic matrices.

- *Application:* Used in pressure vessels, pipes, and rocket motor casings due to high directional
strength.

- *Advantages:* High fiber volume fraction, resulting in improved strength.

**(b) Resin Transfer Molding (RTM):**

- *Materials:* Compatible with various resin systems and reinforcements.

- *Application:* Common in automotive parts and marine components.

- *Advantages:* Low tooling costs, high production rates, and complex part production.

**(c) Wet/Hand Layup:**

- *Materials:* Fibers impregnated with liquid resin.

- *Application:* Used for low-volume production of large components with complex shapes.

- *Advantages:* Low tooling cost and suitability for complex geometries.

**(d) Spray Lay-up:**

- *Materials:* Resin and chopped fibers sprayed onto a mold.

- *Application:* Frequently used in boat manufacturing.

- *Advantages:* Suitable for large parts and complex shapes, cost-effective.

**(e) Pultrusion:**

- *Materials:* Continuous fibers pulled through a resin bath.

- *Application:* Produces structural shapes like rods and tubes.

- *Advantages:* High fiber volume fraction and continuous production.

**(f) Vacuum Bagging:**

- *Materials:* Suitable for various resin and fiber systems.

- *Application:* Widely used in aerospace for lightweight components.

- *Advantages:* Effective for large parts and complex shapes.

### QUESTION THREE

#### (a) Importance of Composite Characterization

- **Importance:**

1. **Quality Assurance:** Ensures adherence to specified standards for reliable performance.

2. **Performance Prediction:** Facilitates predicting behavior under different conditions for

optimized applications.

3. **Material Optimization:** Provides insights into optimizing material composition for specific
properties and applications.

#### Composite Characterization Techniques

1. **Ultrasonic Testing:**

- *Application:* Detects internal defects in composites, ensuring structural integrity.

2. **Thermogravimetric Analysis (TGA):**

- *Application:* Analyzes the thermal stability of composites, crucial for high-temperature

applications.

3. **Scanning Electron Microscopy (SEM):**

 - *Application:* Offers high-resolution images for detailed microstructural analysis, aiding in
understanding material behavior.

#### (b) Steps for Assessing Composite Microstructures

1. **Sample Preparation:**

- *Method:* Cut, polish, and mount the sample to ensure a representative cross-section.

2. **Optical Microscopy:**

- *Method:* Observe the sample under a microscope for surface features, providing insights into the
overall microstructure.

3. **Scanning Electron Microscopy (SEM):**

- *Method:* Use SEM for detailed imaging of the microstructure, revealing finer details of the phases
and interfaces.

4. **Microstructural Analysis:**

- *Method:* Analyze phases, interfaces, and defects to understand how the microstructure influences
material properties.

#### (c) Alumina Fibers Properties and Applications

- **Properties:**

1. **High Strength:** Alumina fibers exhibit high tensile strength, contributing to the overall strength
of the composite.

2. **Temperature Resistance:** Can withstand high temperatures, making them suitable for high-
performance applications.

3. **Chemical Inertness:** Resistant to chemical corrosion, ensuring durability in harsh environments.

- **Applications:**

1. **Aerospace Components:** Used in aircraft and spacecraft structures for their lightweight and
high-strength properties.

2. **Reinforcement in Composites:** Commonly used to enhance the mechanical properties of

composite materials in various industries.

#### (d) Reinforcements in Fiber-Reinforced Composites

**(i) Natural Reinforcements:**

1. **Flax Fibers:** Used in automotive interiors for its lightweight and renewable nature.

2. **Jute Fibers:** Commonly used in construction materials for its cost-effectiveness and
environmental friendliness.

3. **Bamboo Fibers:** Used in various structural applications, known for being lightweight and
environmentally sustainable.

**(ii) Advanced Reinforcements:**

1. **Carbon Fibers:** Widely used in aerospace and sports equipment for its exceptional strength and
stiffness.

2. **Aramid Fibers (e.g., Kevlar):** Used in ballistic applications, providing high tensile strength and
impact resistance.

3. **Glass Fibers:** Commonly used in boat hulls and automotive components for its cost-
effectiveness and moderate strength.

### QUESTION FOUR

#### (a) Benefits of Polymer Composite Materials (PMC)

- **Benefits:**

1. **Weight Reduction:** PMCs are significantly lighter than traditional materials, leading to improved
fuel efficiency.

2. **Corrosion Resistance:** Polymer matrices are inherently resistant to corrosion, ensuring

durability in various environments.

3. **Design Flexibility:** PMC materials can be molded into complex shapes, allowing for innovative
and efficient designs.

4. **High Strength-to-Weight Ratio:** PMCs offer a superior strength-to-weight ratio, contributing to

structural integrity.

- **Applications:**

1. **Aerospace Components:** Used in aircraft components such as wings, fuselage, and interior
components for weight reduction.

2. **Automotive Parts:** Employed in car panels, body parts, and interior components for both
weight reduction and improved performance.

3. **Sports Equipment:** Commonly used in manufacturing sports equipment such as tennis rackets,
bicycle frames, and golf clubs due to its lightweight and durable nature.

#### (b) Continuous Glass Fiber-Reinforced PMC

**(i) Modulus of Elasticity Calculation:**

- *Calculation:* The composite modulus \(E_{composite}\) can be determined using the rule of mixtures:
\(E_{composite} = V_f \times E_f + V_m \times E_m\).

**(ii) Load Carried by Each Phase:**

- *Calculation:* Apply the stress to each phase using the respective volume fractions and moduli.
**(iii) Strain Sustained by Each Phase:**

- *Calculation:* Use Hooke's Law to determine the strain in each phase.

### QUESTION FIVE

#### (a) Reasons for Glass Fibers' Common Use in Reinforcement

1. **High Strength:** Glass fibers offer high tensile strength, contributing to the overall strength of the
composite.

2. **Chemical Inertness:** Glass fibers are resistant to chemical corrosion, ensuring durability in various
environments.

3. **Cost-Effectiveness:** Glass fibers are relatively inexpensive compared to some advanced fibers,
making them economical for various applications.

4. **Availability:** Glass fibers are widely available in the market, providing accessibility for
manufacturers.

#### (b) Importance of Surface Perfection in Glass Fibers

- **Importance:**

- Ensures uniform load transfer and effective stress distribution in the composite.

- Imperfections can act as stress concentrators, leading to premature failure.

- Enhances adhesion between fibers and matrix, improving overall composite performance.

- **Protection Measures:**

1. **Sizing Treatment:** Applied to improve adhesion between fibers and matrix.

2. **Coating:** A protective coating is applied to prevent environmental degradation and enhance

durability.
#### (c) Toughening Mechanisms in Ceramic-Matrix Composites (CMC)

1. **Crack Bridging:** Reinforcing phase bridges the crack, preventing further propagation.

2. **Whisker Toughening:** Fine ceramic whiskers interrupt crack growth, enhancing toughness.

3. **Transformation Toughening:** Phase transformation absorbs energy, resisting crack propagation.

#### (d) Effect of Particulate and Fiber Reinforcement on Mechanical Properties

- **Mechanical Properties:**

1. **Particulate Reinforcement:** Particles resist deformation, enhancing hardness and wear

resistance.

2. **Fiber Reinforcement:** Fibers improve tensile strength, stiffness, and impact resistance.

- **Strengthening Mechanisms:**

1. **Particulate Reinforcement:** Hinders dislocation movement, strengthening the material.

2. **Fiber Reinforcement:** Distributes stress, prevents crack propagation, and enhances overall
strength.

###