MEF452 Composite Materials

and Design/MST G 522

Advanced CompositesL1
BITS Pilani Dr. Sachin Waigaonkar
K K Birla Goa Campus
Overview

• Composite Materials and their Importance

• FRP composites
• Matrix materials
• Types of Fibers
• Fabrication of Composites
• Behavior of Unidirectional Composites
• Short fiber Composites
• Laminated Composites and their Analysis
• Experimental Characterization.
• Emerging Composite materials.

BITS Pilani, K K Birla Goa Campus

Textbooks

T1. B.D. Agrawal L.J. Broutman and K. handrashekhara

“Analysis and Performance of Fiber Composites”, John
Wiley and Sons Inc, 2006
T2. R J Crawford, “Plastics Engineering”, Butterworth
Heinemann, An imprint of Elsevier science.

BITS Pilani, K K Birla Goa Campus

Composites

Composite: Two or more chemically different constituents

combined macroscopically to yield a useful material.

BITS Pilani, K K Birla Goa Campus

Natural Composites

•Granite: Granular
composite of quartz,
feldspar and mica.

Wood: Cellulose fibers bound by lignin matrix

•Bone: Hard and Brittle Hydroxyapatite +

Soft and Flexible Collagen ( A Protein)

BITS Pilani, K K Birla Goa Campus

 Man Made Composites

•Plywood: Several layers of wood veneer glued

together
Concrete:[Particulate composite of aggregates
(limestone or granite), sand, cement and water .

•Fibrous composites: Variety of fibers (glass, kevlar,

Ceremets: Ceramic and metal composites
graphite, nylon, etc.) bound together by a polymeric matrix
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These are not Composites

• Plastics: Even though they may have several

“fillers”, their presence does not alter the physical
properties significantly.
• Alloys: Here the alloy is not macroscopically
heterogeneous, especially in terms of physical
properties.
• Metals with impurities: The presence of impurities
does not significantly alter physical properties of the
metal.

BITS Pilani, K K Birla Goa Campus

Properties of Conventional Materials
and bi-directional FRPSs
Material Vf Tensile Tensile Density Specific Specific
Modulus Strength (ρ) g/cm3 Modulus Strengrh
( E) GPa (σu) GPa (E/ρ) (σu/ρ)
Mild Steel 210 0.45-0.83 7.8 26.9 0.058-
0.106
Aluminum 73 0.41 2.7 27.0 0.152
E-Glass 57 21.5 0.57 1.97 10.9 0.26
Epoxy
Kevlar 49 60 40 0.65 1.40 29.0 0.46
Epoxy
Carbon 58 83 0.38 1.54 53.5 0.24
Fiber-
Epoxy
Boron- 60 106 0.38 2.00 53.0 0.19
Epoxy

BITS Pilani, K K Birla Goa Campus

1994 Average Production Car
(Mass=1439 Kg)

6 Iron and Steel

8
Other Metals
10
Other Materials
Rubber, Glass etc.
8
Plastics and
68 Composites
Fuel, other fluids
and lubricants

BITS Pilani, K K Birla Goa Campus

Concept Car of Future
(Mass< 600 Kg)

Iron and Steel

3
16
Other Metals (Al, Cu,
Brass, Mg, etc.)
Other Materials
43 Rubber, Glass etc.
Plastics and
26 Composites
Fuel, other fluids and
lubricants
12

BITS Pilani, K K Birla Goa Campus

Composites in Cars

BITS Pilani, K K Birla Goa Campus

BITS Pilani, K K Birla Goa Campus
Tata Motors Composite Materials Low
Cost Car
Composite based on Poly-diallyl-phthalate ( PDP)

Ref: http://articles.economictimes.indiatimes.com/2013-02-23/news/37257394_1_ultra-
low-cost-car-tata-car-premium-small-car
BITS Pilani, K K Birla Goa Campus
Composite Materials : Aerospace

BITS Pilani, K K Birla Goa Campus

Composites in LCA-Tejas

BITS Pilani, K K Birla Goa Campus

Benefits of Composites in LCA-Tejas

• 40% reduction in the total number of parts compared to

using a metallic frame.
• Number of fasteners has been reduced by half from the
10,000 ( in a typical metallic frame design. )
• The composite design also helped to avoid about 2,000
holes being drilled into the airframe.
• Overall, the aircraft's weight is lowered by 21%.
• Shorter time required to assemble the aircraft — typically
seven months as opposed to 11 months using an all-
metal airframe.
• Significant cost savings

BITS Pilani, K K Birla Goa Campus

Repeating Units of Common
Polymers

From
Callister’s Materials Science and
Engineering, Adapted Version.

BITS Pilani, K K Birla Goa Campus

 Repeating Units of Common
Polymers

From
Callister’s Materials Science and
Engineering, Adapted Version.

BITS Pilani, K K Birla Goa Campus