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The Science and Engineering of Materials, 4 Ed
The Science and Engineering of Materials, 4 Ed
of Materials, 4th ed
Donald R. Askeland Pradeep P. Phul
Objectives of Chapter 16
Chapter Outline
16.1
16.2
16.3
16.4
Dispersion-Strengthened Composites
Particulate Composites
Fiber-Reinforced Composites
Characteristics of Fiber-Reinforced
Composites
16.5 Manufacturing Fibers and Composites
16.6 Fiber-Reinforced Systems and
Applications
16.7 Laminar Composite Materials
16.8 Examples and Applications of Laminar
Composites
16.9 Sandwich Structures
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Section 16.1
Dispersion-Strengthened Composites
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Figure 16.2
Comparison of the yield
strength of dispersionstrengthened sintered
aluminum powder
(SAP) composite with
that of two
conventional two-phase
high-strength
aluminum alloys. The
composite has benefits
above about 300C. A
fiber-reinforced
aluminum composite is
shown for comparison.
Example 16.1
TD-Nickel Composite
Suppose 2 wt% ThO2 is added to nickel. Each ThO2 particle
has a diameter of 1000 . How many particles are present
in each cubic centimeter?
Example 16.1 SOLUTION
The densities of ThO2 and nickel are 9.69 and 8.9 g/cm3,
respectively. The volume fraction is:
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Section 16.2
Particulate Composites
Rule of mixtures - The statement that the properties of a
composite material are a function of the volume fraction
of each material in the composite.
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Example 16.2
Cemented Carbides
A cemented carbide cutting tool used for machining contains 75
wt% WC, 15 wt% TiC, 5 wt% TaC, and 5 wt% Co. Estimate the
density of the composite.
Example 16.2 SOLUTION
First, we must convert the weight percentages to volume
fractions. The densities of the components of the composite
are:
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Example 16.3
Silver-Tungsten Composite
A silver-tungsten composite for an electrical contact is
produced by first making a porous tungsten powder metallurgy
compact, then infiltrating pure silver into the pores. The density
of the tungsten compact before infiltration is 14.5 g/cm 3.
Calculate the volume fraction of porosity and the final weight
percent of silver in the compact after infiltration.
Example 16.3 SOLUTION
From the rule of mixtures:
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Example 16.4
Design of a Particulate Polymer Composite
Design a clay-filled polyethylene composite suitable for injection
molding of inexpensive components. The final part must have a
tensile strength of at least 3000 psi and a modulus of elasticity of
at least 80,000 psi. Polyethylene costs approximately 50 cents per
pound and clay costs approximately 5 cents per pound. The density
of polyethylene is 0.95 g/cm3 and that of clay is 2.4 g/cm3.
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Section 16.3
Fiber-Reinforced
Composites
The Rule of Mixtures
in Fiber-Reinforced Composites
Strength of Composites - The tensile strength of a fiberreinforced composite (TSc) depends on the bonding
between the fibers and the matrix.
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Example 16.5
Rule of Mixtures for Composites:
Stress Parallel to Fibers
Derive the rule of mixtures (Equation 16.5) for the modulus of
elasticity of a fiber-reinforced composite when a stress ( ) is
applied along the axis of the fibers. We use the symbol for
stress to distinguish it from the symbol used for conductivity.
Example 16.5 SOLUTION
The total force acting on the composite is the sum of the forces
carried by each constituent:
Since F = A:
Fc = Fm + Ff
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Example 16.6
Modulus of Elasticity for Composites:
Stress Perpendicular to Fibers
Derive the equation for the modulus of elasticity of a fiberreinforced composite when a stress is applied perpendicular to the
axis of the fiber (Equation 16-7).
Example 16.6 SOLUTION
The strains are no longer equal; instead, the weighted sum of the
strains in each component equals the total strain in the composite,
whereas the stresses in each component are equal (iso-stress
conditions):
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Example 16.7
Boron Aluminum Composites
Boron coated with SiC(or Borsic) reinforced aluminum
containing 40 vol% fibers is an important hightemperature, lightweight composite material. Estimate the
density, modulus of elasticity, and tensile strength parallel
to the fiber axis. Also estimate the modulus of elasticity
perpendicular to the fibers.
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Example 16.8
Nylon-Glass Fiber Composites
Boron coated with SiC(or Borsic) reinforced aluminum
containing 40 vol% fibers is an important hightemperature, lightweight composite material. Estimate the
density, modulus of elasticity, and tensile strength parallel
to the fiber axis. Also estimate the modulus of elasticity
perpendicular to the fibers.
Example 16.8 SOLUTION
The modulus of elasticity for each component of the
composite is:
Eglass = 10.5 106 psi Enylon = 0.4 106 psi
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Section 16.4
Characteristics of Fiber-Reinforced
Composites
Many factors must be considered when designing a fiberreinforced composite, including the length, diameter,
orientation, amount, and properties of the fibers; the
properties of the matrix; and the bonding between the
fibers and the matrix.
Aspect ratio - The length of a fiber divided by its
diameter.
Delamination - Separation of individual plies of a fiberreinforced composite.
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Figure 16.14
Comparison of the
specific strength and
specific modulus of
fibers versus metals
and polymers.
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Example 16.9
Design of an Aerospace Composite
We are now using a 7075-T6 aluminum alloy (modulus of
elasticity of 10 106 psi) to make a 500-pound panel on a
commercial aircraft. Experience has shown that each pound
reduction in weight on the aircraft reduces the fuel consumption
by 500 gallons each year. Design a material for the panel that
will reduce weight, yet maintain the same specific modulus, and
will be economical over a 10-year lifetime of the aircraft.
Example 16.9 SOLUTION
lets consider using a boron fiber-reinforced Al-Li alloy in the T6
condition. The specific modulus of the current 7075-T6 alloy is:
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Section 16.5
Manufacturing Fibers and Composites
Chemical vapor deposition - Method for manufacturing
materials by condensing the material from a vapor onto
a solid substrate.
Carbonizing - Driving off the non-carbon atoms from a
polymer fiber, leaving behind a carbon fiber of high
strength. Also known as pyrolizing.
Filament winding - Process for producing fiber-reinforced
composites in which continuous fibers are wrapped
around a form or mandrel.
Pultrusion - A method for producing composites
containing mats or continuous fibers.
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Figure 16.17 Methods for producing (a) boron and (b) carbon
fibers.
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Section 16.6
Fiber-Reinforced Systems and
Applications
Advanced Composites - The advanced composites
normally are polymermatrix composites reinforced with
high-strength polymer, metal, or ceramic fibers.
Metal-Matrix Composites - These materials,
strengthened by metal or ceramic fibers, provide hightemperature resistance.
Ceramic-Matrix Composites - Composites containing
ceramic fibers in a ceramic matrix are also finding
applications.
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Figure 16.28 A
comparison of the
specific strength of
various carbon-carbon
composites with that
of other hightemperature materials
relative to
temperature.
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Example 16.10
Design of a Composite Strut
Design a unidirectional fiber-reinforced epoxy-matrix
strut having a round cross-section. The strut is 10 ft long
and, when a force of 500 pounds is applied, it should
stretch no more than 0.10 in. We want to assure that the
stress acting on the strut is less than the yield strength
of the epoxy matrix, 12,000 psi. If the fibers should
happen to break, the strut will stretch an extra amount
but may not catastrophically fracture. Epoxy costs about
$0.80/lb and has a modulus of elasticity of 500,000 psi.
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Although the carbon fibers are the most expensive, they permit
the lightest weight and the lowest material cost strut. (This
calculation does not, however, take into consideration the costs
of manufacturing the strut.) Our design, therefore, is to use a
0.255-in.-diameter strut containing 0.183 volume fraction high
modulus carbon fiber.
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Section 16.7
Laminar Composite Materials
Rule of Mixtures - Some properties of the laminar
composite materials parallel to the lamellae are
estimated from the rule of mixtures.
Producing Laminar Composites - (a) roll bonding, (b)
explosive bonding, (c) coextrusion, and (d) brazing.
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Section 16.8
Examples and Applications of
Laminar Composites
Laminates - Laminates are layers of materials joined by
an organic adhesive.
Cladding - A laminar composite produced when a
corrosion-resistant or high-hardness layer of a laminar
composite formed onto a less expensive or higherstrength backing.
Bimetallic - A laminar composite material produced by
joining two strips of metal with different thermal
expansion coefficients, making the material sensitive to
temperature changes.
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Section 16.9
Sandwich Structures
Sandwich - A composite material constructed of a
lightweight, low-density material surrounded by dense,
solid layers. The sandwich combines overall light weight
with excellent stiffness.
Honeycomb - A lightweight but stiff assembly of
aluminum strip joined and expanded to form the core of
a sandwich structure.
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Figure 16.32 (a) A hexagonal cell honeycomb core, (b) can be joined to
two face sheets by means of adhesive sheets, (c) producing an
exceptionally lightweight yet stiff, strong honeycomb sandwich structure.
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