Professional Documents
Culture Documents
COMPOSITES
LECTURE 15:
COMPOSITE
MATERIALS
By: Casey Keulen
MECH 473 ~ LECTURE 15:
COMPOSITES
COMPOSITES
-Composite materials are engineered materials made
from two or more constituent materials that remain
separate and distinct while forming a single component
COMPOSITES
COMPOSITES
Composites can be found in:
-Boat hulls
-The aerospace industry (structural components as well
as engines and motors)
-Automotive parts (panels, frames, dashboards, body
repairs)
-Sinks, bathtubs, hot tubs, swimming pools
-Cement buildings, bridges
-Surfboards, snowboards, skis
-Golf clubs, fishing poles, hockey sticks
-Trees are technically composite materials, plywood
-Electrical boxes, circuit boards, contacts
-Everywhere
MECH 473 ~ LECTURE 15:
COMPOSITES
COMPOSITES
Composites can be classified by their
matrix material which include:
-Metal matrix composites (MMC’s)
COMPOSITES
MMC - Metal Matrix Composites
-The matrix is relatively soft and flexible.
-The reinforcement must have high strength and stiffness
-Since the load must be transferred from the matrix to the
reinforcement, the reinforcement-matrix bond must be strong.
MMC use:
-Two types of particulates ( dispersion strengthened alloys
and regular particulate composites)
-Or long fiber reinforcements
MECH 473 ~ LECTURE 15:
COMPOSITES
COMPOSITES
PMC - Polymer Matrix Composites
-The matrix is relatively soft and flexible
-The reinforcement must have high strength and stiffness
-Since the load must be transferred from matrix to
reinforcement, the reinforcement-matrix bond must be strong
DISPERSION STRENGTHENED
MMC’S
-Dispersion strengthened alloys can be considered as composites
because there is little or no interaction between the two components
and the reinforcement is not soluble in the metal matrix.
-The dispersoids are usually 10-250 nm diameter oxide particles and
are introduced by physical means rather than chemical precipitation.
-They are located within the grains and at grain boundaries but are not
coherent with the matrix as in precipitation hardening
-The dispersed particles are sufficiently small in size to impede
dislocation movement and thus improve yield strength as well as
stiffness.
-Dispersion strengthened alloys are somewhat weaker than precipitation
hardened alloys at room temperature but since overaging, tempering,
grain growth or particle coarsening do not occur on heating, they are
stronger and more creep resistant at high temperatures.
MECH 473 ~ LECTURE 15:
COMPOSITES
SINTERED ALUMINUM
POWDER (SAP) COMPOSITES
-SAPs have an aluminum matrix with aluminum oxide
(Al2O3) particulate
-The matrix can be strengthened by %14
SINTERED ALUMINUM
POWDER (SAP) COMPOSITES
Properties of SAP
compared to 2024-T8,
7075-T6 and a boron
fiber strengthened
1100 alloy.
MECH 473 ~ LECTURE 15:
COMPOSITES
THORIA-DISPERSED
COMPOSTIES
-An important group of dispersion-strengthened composites is
thoria-dispersed (TD) metals
-Thorium is an element on the periodic table (atomic number 90)
-A common example is TD-nickel
CEMENTED CARBIDES
(CERMETS)
-Cemented carbides are an example of regular particulate MMC’s
(as opposed to dispersion strengthened MMC’s)
-Carbides such as WC (tungsten-carbide) are used for cutting tool
inserts but this hard ceramic is very brittle so it cracks or chips
under impact loads, to remedy this cobalt is used as a matrix
-Co-WC (cobalt tungsten-carbide) cermets are produced by
pressing Co and W powders into compacts, which are heated
above the melting point of Co
-On cooling the carbide particles become embedded in the
solidified Co, which act as a tough matrix for the WC particles
-In addition to its strength and toughness, Co is also selected
because it wets the carbide particles to give a strong bond
MECH 473 ~ LECTURE 15:
COMPOSITES
CEMENTED CARBIDES
(CERMETS)
-Cemented carbides are commonly used as inserts for
cutting tools
CAST METAL
PARTICULATE MMC’S
-Al alloys for automotive connecting rods and pistons can be
strengthened and hardened by the addition of SiC (silicon
carbide) particles.
-The SiC particles are introduced at a temperature at which the
alloy is in the solid plus liquid state, ie., by “compocasting”.
MECH 473 ~ LECTURE 15:
COMPOSITES
CAST METAL
PARTICULATE MMC’S
Compocasting of Al-SiC:
-Partially solidified alloy is stirred to break up dendrites (fig. a)
-Particles of SiC are added at this temperature (fig. b)
-In a pressure die casting machine, the solid mixture becomes
thixotropic to form a high density casting (fig. c)
MECH 473 ~ LECTURE 15:
COMPOSITES
CAST METAL
PARTICULATE MMC’S
RULE OF MIXTURES
rc f m rm f f r f Note that f m 1 f f
RULE OF MIXTURES
For fiber reinforced composites, the rule of mixtures predicts
the density of the composite as well as electrical and
thermal conductivity along the direction of the fibers if they
are continuous and unidirectional.
Density, r, is given as a fraction, f, as:
rc f m rm f f r f Note that f m 1 f f
For thermal conductivity: For electrical conductivity:
Kc fm Km f f K f c f m m f f f
Thermal and electrical energy can be transferred through the
composite at a rate that is proportional to the volume fraction,
f of the conductive material
MECH 473 ~ LECTURE 15:
COMPOSITES
RULE OF MIXTURES
In a composite material with a metal matrix and ceramic
fibers, the bulk of the energy would be transferred
through the matrix.
In a composite consisting of a polymer matrix containing
metallic fibers, the energy would be transferred
through the fibers.
When the fibers are not continuous or unidirectional, the
simple rule of mixtures may not apply.
For example, in a metal fiber-polymer matrix composite,
electrical conductivity would be low and would
depend on the length of the fibers, the volume
fraction of fibers and how often the fibers touch one
another.
MECH 473 ~ LECTURE 15:
COMPOSITES
RULE OF MIXTURES
The rule of mixtures can also be used to predict the modulus of
elasticity when the fibers are continuous and unidirectional.
Ec f f E f
MECH 473 ~ LECTURE 15:
COMPOSITES
RULE OF MIXTURES
FIBER REINFORCED
COMPOSITES
-Fiber reinforced composites provide improved strength,
fatigue resistance, Young’s modulus and strength to
weight ratio over the constituent materials.
CHARACTERISTICS OF FIBER
REINFORCED COMPOSITES
CHARACTERISTICS OF FIBER
REINFORCED COMPOSITES
Fiber length and diameter: Fiber dimensions are characterized by
their aspect ratio l/d where l is the fiber length and d is the
diameter.
The strength improves when the aspect ratio is large.
Typical fiber diameters are from 10 mm to 150 mm.
Fibers often fracture because of surface imperfections. Making
the diameter small reduces its surface area, which has fewer
flaws.
Long fibers are preferred because the ends of the fiber carry less
of the load. Thus the longer the fiber, the fewer the ends and the
higher the load carrying capacity of the fibers.
MECH 473 ~ LECTURE 15:
COMPOSITES
CHARACTERISTICS OF FIBER
REINFORCED COMPOSITES
FIBER ORIENTATION
-Maximum strength is
obtained when long fibers are
oriented parallel to the
applied load
-The effect of fiber orientation
and strength can be seen in
the plot
MECH 473 ~ LECTURE 15:
COMPOSITES
FIBER ORIENTATION
FIBER ORIENTATION
-A three dimensional
weave is also possible
FIBER PROPERTIES
FIBER PROPERTIES
TYPES OF FIBERS
Some commonly used fibers for polymer matrix composites:
-Glass fibers
-Carbon fibers
-Aramid fibers
CARBON FIBERS
ARAMID FIBERS
-Aramid fibers are also becoming more and more
common
COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT
-Filament: a single thread like fiber
-Roving: a bundle of filaments wound to form a large
strand
-Chopped strand mat: assembled from chopped filaments
bound with a binder
-Continuous filament random mat: assembled from
continuous filaments bound with a binder
-Many varieties of woven fabrics: woven from rovings
MECH 473 ~ LECTURE 15:
COMPOSITES
COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT
COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT
COMMERCIALLY AVAILABLE
FORMS OF REINFORCEMENT
MATRIX MATERIALS
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING WITH
POLYMER MATRIX MATERIALS
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
-The method of manufacturing composites is very
important to the design and outcome of the product
-With traditional materials one starts out with a blank piece
of material ie: rod, ingot, sheet, etc and works it to produce
the desired part.
-However, this is not the case with polymer-matrix
composites.
-With these composites the material and the component
are being produced at the same time, therefore we aim for
the product to be a net or near net shape with little to no
post processing
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Hand Lay-Up/Spray-Up
-Oldest and most commonly used manufacturing method
-Usually used to produce polyester or epoxy resin parts such as boat
hulls, tanks and vessels, pick-up truck canopies
-The method is quite simple, the resin and reinforcement is placed
against the surface of an open (one sided) mold and allowed to cure or
in the case of spray-up the resin/reinforcement is sprayed onto the
mold with a spray gun
-Often a gel coat is applied to the mold prior to
produce a better surface quality and protect the
composite from the elements
-A gel coat is a resin usually 0.4 to 0.7 mm
thick, commonly seen on the outer surface of
smaller boats
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Hand Lay-Up/Spray-Up
-The pros of this process include: low initial start up cost, easy to
change mold/design, on-site production possible (ie portable process)
-The cons include: labor intensive, the quality of parts depends on
operator’s skill and therefore inconsistent, only one good side to the part
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Prepreg
-A pregreg (short for preimpregnated) is a composite that
comes with the resin already added to the reinforcement
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Prepreg
-Prepreg can be used in a few different ways
-It can be placed against a mold similar to the hand lay-up method
-Once placed in the mold the material must be compressed and cured
according to a specific pressure/temperature cycle
-This is often done by means of a vacuum bag where a thin plastic cover is
secured overtop of the composite and the air is vacuumed out
-This process can reduce manufacturing time and produce a stronger part
(if a knitted preform is used)
-Another process used is ‘automated tape lay-up’
-This process uses a large automated roller similar to a packing tape roller
-The roller applies the tape with pressure which eliminates the need for a
vacuum bag
- Automated tape lay-up is used to produce large parts, generally in
aerospace applications and is also capable of 3-d parts
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Pultrusion
-Similar to extrusion of metal parts
-Pultrusion involves pulling resin-impregnated glass strands through a die
-Standard extruded shapes can easily be produced such as pipes,
channels, I-beams, etc.
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Pultrusion
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Filament Winding
-A continuous reinforcement, either previously impregnated or impregnated
during winding is wound around a rotating mandrel to form a composite part
-Pros: fast lay-up speed, very accurate and repeatable product, possibility to
use continuous fiber
-Cons: expensive equipment, high cost for mandrel, poor surface finish,
some shapes not possible
-Examples: oxygen bottles for firemen, rocket motors, tennis rackets, shafts
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Filament Winding
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Filament Winding
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Resin Transfer Molding
-Resin transfer molding is a manufacturing method that is
quite similar to injection molding where plastic is injected
into a closed mold
-In the RTM process the preform (precut piece(s) of
reinforcement) is placed in the mold, the mold is closed
and the thermoset plastic matrix is injected into the mold,
once the matrix is cured the part is ejected
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Resin Transfer Molding
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Resin Transfer Molding
Pros:
-Complex components can be produced
-Components have two good surfaces
-Component can be created within a fairly tight tolerance
-High level of repeatability
-Process can be automated and repeated
-Process can be numerically modeled and analyzed
Cons:
-Molds often need to be designed using trial and error methods
-‘race tracking’ may occur
-‘wash out’ may occur
-Air voids are easily formed with poor process parameters
MECH 473 ~ LECTURE 15:
COMPOSITES
MANUFACTURING OF POLYMER-
MATRIX COMPOSITES
Resin Transfer Molding
THE END
ANY QUESTIONS?