Chapter 15: Composites: Many Engineering Components Are Composites

Chapter 15: Composites
Many engineering components are composites
1
MSE 280: Introduction to Engineering Materials ©D.D. Johnson 2004, 2006-2008
Chapter 15: Composites
ISSUES TO ADDRESS...
• What are the classes and types of composites?
• Why are composites used instead of metals,
ceramics, or polymers?
• How do we estimate composite stiffness & strength?
• What are some typical applications?
2
Classification of Composites
• Composites: cross
woven
0.5 mm
- Multiphase material w/significant fibers
section
proportions of ea. phase. view
• Matrix:
- The continuous phase
- Purpose is to:
transfer stress to other phases
protect phases from environment
- Classification: MMC, CMC, PMC
metal ceramic polymer
• Dispersed phase:
-Purpose: enhance matrix properties. From D. Hull and T.W. Clyne, An Intro to
Composite Materials, 2nd ed., Cambridge
MMC: increase sy, TS, creep resist. University Press, New York, 1996, Fig.
3.6, p. 47.
CMC: increase Kc
PMC: increase E, sy, TS, creep resist.
-Classification: Particle, fiber, structural
3
COMPOSITE SURVEY: Particle-I
Structural
Fiber -reinforced
Particle-reinforced
• Examples:
WC/Co
Automobile
matrix:
particles:
V
60μm
0.75
600μm :μm
matrix:
-Spheroidite
--/m
cementite
cobalt
WC
rubber
C
ferrite ( α)
cemented
tires
10-15vol%!
steel
(Fe3C )
(ductile)
(brittle,
(compliant)
(stiffer) Adapted from Fig.
hard) carbide 10.10, Callister 6e.
(brittle)
Adapted from Fig. 16.4,

Callister 6e.
Adapted from Fig. 16.5,

Callister 6e.
4
COMPOSITE SURVEY: Particle-II
Structural
Fiber -reinforced
Particle-reinforced
• Elastic modulus, Ec, of composites:
+
=m
c
p
u
E
V
(W)
10
80
60
40
200Cu)
150
30
250pper
cE(GPa)
Data:
2
0
vol%
350
“rule
0 of
lower
1 :limit:
tungsten
mixtures”
limit:
-- twoCu
approaches.
matrix
w/tungsten
particles
Fig. 15.3
• Application to other properties:

-- Electrical conductivity, se: Replace E by se.
-- Thermal conductivity, k: Replace E by k.
5
COMPOSITE SURVEY: Fiber-I
Structural
Particle-reinforced
Fiber-reinforced
• Aligned Continuous fibers
• Ex: --Metal: g'(Ni3Al)-a(Mo) --Glass w/SiC fibers
formed by glass slurry
2μm by eutectic
fibers:
matrix: γ’α ()(Nisolidification.
Mo)
3Al)
(ductile)
(brittle)
Eglass = 76GPa; ESiC = 400GPa.
(a)
From F.L. Matthews and R.L.

Rawlings, Composite Materials;
Engineering and Science, Reprint ed.,
CRC Press, Boca Raton, FL, 2000. (a)
Fig. 4.22, p. 145 (photo by J. Davies);
(b) (b) Fig. 11.20, p. 349 (micrograph by
From W. Funk and E. Blank, “Creep deformation of H.S. Kim, P.S. Rodgers, and R.D.
Ni3Al-Mo in-situ composites", Metall. Trans. A Vol. Rawlings).
19(4), pp. 987-998, 1988.
6
COMPOSITE SURVEY: Fiber-II
Structural
Particle-reinforced
Fiber-reinforced
• Discontinuous, random 2D fibers
• Example: Carbon-Carbon fibers
C fibers:
matrix:
view lie plane
onto
lessplane
in
very stiff
stiff
--process: fiber/pitch, then
verystrong
less strong
burn out at up to 2500C.
--uses: disk brakes, gas (b)
turbine exhaust flaps, nose
cones.
(a)
• Other variations:
--Discontinuous, random 3D
--Discontinuous, 1D
7
Elasticity of Composites
Stress-strain response depends on properties of
• reinforcing and matrix materials (carbon, polymer, metal, ceramic)
• volume fractions of reinforcing and matrix materials
• orientation of fibre reinforcement (golf club, kevlar jacket)
• size and dispersion of particle reinforcement (concrete)
• absolute length of fibres, etc.
concentration size shape
distribution orientation
8
Families of Composites:
particle, fibre, structural reinforcements
ceramics
Twisting,
Bending
Orientation dependence
9
Two simplest cases: Iso-load and Iso-strain
Isostrain: Load & Reinforcements Aligned
F
% Vα Strain or elongation of matrix
Vα =
VTot and fibers are the same!
Volume fraction Ec = ∑α =1,N Eα V%α

F
Isoload:Load & Reinforcements Perpendicular
(Isostress below)
F
Load (Stress) across matrix
and fibers is the same!
1 V%α
= ∑α =1,N
Ec Eα
F 10
Isostrain Case in Ideal Composites
F
Isostrain Case: strain εc = ε m = ε r
forces Fc = Fm + Fr
F
Load is distributed over matrix and fibers, so cAc = mAm + fAf.
σ c = σ m (Am / Ac ) + σ f (A f / Ac ) *if the fibers are
continuous, then volume
or σ c = σ mV% %
m + σ f Vf fraction is easy.
For Elastic case: σ c = ε c Ec = ε m EmV% % % %

m + ε f E f V f = ε c (E mVm + E f V f )
Composite Property: Pc = ∑α =1,N PαV%α * like law of mixtures
Properties include: elastic moduli, density, heat capacity,

thermal expansion, specific heat, ...
11
Iso-Load Case for Ideal Composites
Isoload Case: strain εc = ε m + ε r
forces Fc = Fm = Fr
Without de-bonding, loads are equal, therefore, strains must add, so
% % ⎛σ ⎞% ⎛σ ⎞
% *if the fibers are continuous or
elastic case ε c = ε mVm + ε f V f = ⎜ ⎟ Vm + ⎜ ⎟Vf
⎝ Em ⎠ ⎝ Ef ⎠ planar, then area of applied
stress is the same.
1 V%α
Composite Property: = ∑α =1,N
Pc Pα * like resistors in parallel.
Properties include: elastic moduli, density, heat capacity,

thermal expansion, specific heat, ...
12
ISOSTRAIN Example
Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre

reinforcements of glass (E = 76 GPa).
What is Elastic Modulus?
Ec = V˜ m E m + V˜ fE f=(1−V˜ f)Em +V˜ fEf≈V˜ fEf

= 26.7 GPA ~ 25 GPA
* Stiffness of composite under isostrain is dominated by fibers.
13
ISOLOAD Example
Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre

reinforcements of glass (E = 76 GPa).
What is Elastic Modulus? 1 V

˜ V
˜
= m+ f
Ec Em Ef
Rearrange: Em Ef Em
E= C ≈ = 3.8 GPA
V˜ fE m +(1−V˜ f)E f (1−V˜ f)
* Elastic modulus of composite under isoload condition strongly

depends on stiffness of matrix, unlike isostrain case where
stiffness dominates from fibers.
14
Modulus of Elasticity in Tungsten Particle Reinforced Copper
isostrain
isoload
•Particle reinforcements usually fall in between two extremes.
15
Simplified Examples of Composites
Are these isostrain or isoload?
What are some real life examples?
16
Simplified Examples of Composites
A B ||
Load, F
• Material A and B are different • Fiber reinforced epoxy cylinder
• e.g., walkway, trapeze bar,… • e.g, pressure cylinder
unloading
3" 4" 6"
200,000
F A F
60,000
permanent
strain. ε
ε
0
• welded tubular composite
17
Self-Assessment Example: isostrain
A platform is suspended by two parallel rods (A and B).
A B Yielding of either rod of this “composite” constitutes
failure, such as the falling (and possible death) of the
trapeze artist, the people using the walkway, etc.
Each rod is 1.28 cm in diameter.
Load, F Rod A is 4340 steel, with E= 210 GPa, ys= 855 MPa.
Rod B is 7075-T6 Al alloy, with E= 70 GPa, ys= 505 MPa.
(a) What uniform load can be applied to the platform before yielding will occur?
If not elastic, then composite fails, due to permanent deformation! Hence
σA
ys 855M Pa 3 σ Bys 505M Pa ∴ εC ≤εA < εB
εA = = = 4.07x10− εB = = = 7.21x10−3
E A 210G Pa EB 70G Pa
F = FA + FB = A rod (σ A + σB )= A rod (E A εA + E B εB )= A rod εrod (E A + E B )

€ €
−2 2
π (1.28x 10 m)
∴ F= (4.07x10−3 )(210 + 70)G Pa = 146.6kN
4
€
(b) Which rod will be first to yield? Justify and explain your answer.
∴ €εC ≤εA < εB Steelyieldsfirst! To justify, consider how much load is carried FA/FB
relative to that expected from the YS.
18
COMPOSITE SURVEY: Fiber-III
Structural
Particle-reinforced
Fiber-reinforced
• Critical fiber length for effective stiffening & strengthening:
fiber strength in tension fiber diameter
σfd
fiber length > 15 shear strength of
τc fiber-matrix interface
• Ex: For fiberglass, fiber length > 15mm needed
• Why? Longer fibers carry stress more efficiently!
Shorter, thicker fiber: Longer, thinner fiber:
σ d σ d
fiber length < 15 f fiber length > 15 f
τc τc
σ(x) σ(x)
Adapted from Fig.15.7
Poorer fiber efficiency Better fiber efficiency

19
COMPOSITE SURVEY: Fiber-IV
Structural
Particle-reinforced
Fiber-reinforced
• Estimate of Ec and TS: σ fd

--valid when fiber length > 15
τc
-- Elastic modulus in fiber direction:

Ec = E m Vm + KE fVf
efficiency factor:
--aligned 1D: K = 1 (anisotropic)
--random 2D: K = 3/8 (2D isotropy) Values from Table 15.3
--random 3D: K = 1/5 (3D isotropy)
--TS in fiber direction:
(TS)c = (TS )m Vm +(TS )fVf (aligned 1D)
20
COMPOSITE SURVEY: Structural
Fiber -reinforced
Particle-reinforced
Structural
• Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0/90
-- benefit: balanced, in-plane stiffness
Fig. 15.16
• Sandwich panels
-- low density, honeycomb core
-- benefit:
sheetlayersmall weight, large bending stiffness
adhesive
honeycomb
face
Fig. 15.17
21
Composite Benefits
•un-reinf
CMCs:
fiber
particle-reinf
Bend
Force -reinf Increased toughness
d isplacement • PMCs: Increased E/r
3
.3
1
.1
.01
30
032
polymers
metal/
ceramics
PMCs
K=E
G=3E/8
E(GPa)
10
Density, ρ [Mg/m 3]
metal alloys
10
50
30
20
200
ss-4
6061 -1)
0 (sAl
-10
-8
-6
σ(MPa)
ε10
w/SiC
• MMCs: whiskers Adapted from T.G. Nieh, "Creep rupture of a
Increased silicon-carbide reinforced aluminum
composite", Metall. Trans. A Vol. 15(1), pp.
creep 139-146, 1984.
resistance
22
Laminate Composite (Ideal) Example
Gluing together these composite layers

composed of epoxy matrix (Em= 5 GPa)
with graphite fibres (Ef= 490 GPa and
Vf = 0.3). Central layer is oriented 900
from other two layers.
Case I - Load is applied parallel to fibres in outer two sheets.
Case II - Load is applied parallel to fibres of central sheet.
What are effective elastic moduli in the two case?
• First need to know how individual sheets respond, then average.
1 0.3 0.7
= + → E⊥ = 7.1 G Pa For isoload case.
E⊥ 490 G Pa 5 G Pa
E|| = 0.3(490 G Pa)+ 0.7(5 G Pa)→ E|| = 150.5 G Pa For isotrain case.
Case I: Elam=(2/3)(150.5 GPa) + (1/3)(7.1 GPa) = 102.7 GPa
Case II: Elam=(1/3)(150.5 GPa) + (2/3)(7.1 GPa) = 54.9 GPa

23
Mechanical Response of Laminate: Complex, NOT Ideal
3 Conditions required: consider top and bottom before laminated

• strain compatibility- top and bottom must have same strain when glued.
• stress-strain relations - need Hooke’s Law and Poisson effect.
• equilibrium - forces and torques, or twisting and bending.
E
Isostrain for load
σ top = top σ bott
along x-dir: x E x
bott
Poisson Effect and E
Displacements in D: Δtop = top Δbott
y E y
bott
• When glued together displacements have to be same!

• Unequal displacements not allowed!
So, top gets wider (ytop > 0) and bottom gets narrower (ybott < 0).
Equilibrium: Fy = 0 = (ybot tbot + ytop ttop)L. (t = thickness)

24
COMPATIBILITY: When glued, displacements have to be same!
As stress is applied, compatibility can be maintained, depending

on the laminate, only if materials twists.
25
Symmetry of laminate composite dictates properties
Elastic constants are different for different symmetry laminates.
26
Orientation of layers dictates response to stresses
Want compressive stresses at end of

laminate so there are no tensile
stresses to cause delamination - failure!
27
NO delamination - failure!
Apply in-pane Tensile Stress

A B
+90 +45
+45 –45
–45 +90
–45 +90
+45 –45
+90 +45
Tensile -> delaminate
Compressive
28
Why Laminate Composite is NOT Ideal
• Depending on placement of load and the orientation of fibers internal

to sheet and the orientation of sheets relative to one another, the
response is then very different.
• Examples of orientations of laminated sheets that provided

compressive stresses at edges of composite and also tensile stresses
there. >>>> Tensile stresses lead to delamination!
• The stacking of composite sheets and their angular orientation can be

used to prevent “twisting” moments but allow “bending” moments.
This is very useful for airplane wings, golf club shafts (to prevent
slices or hooks), tennis rackets, etc., where power or lift comes or is
not reduced from bending.
29
Thermal Stresses in Composites
• Not just due to fabrication, rather also due to thermal expansion
differences between matrix and reinforcements Tm and Tr.
m r
• Thermal coatings, e.g. σ ≈|αT – αT |ΔTE = ΔαT ΔTE c
If forced to be
At T1 compatible,
At T2 composite will
€ bend and rotate
• Material with most contraction (least) has positive (negative) residual

stress. (For non-ceramics, you should consider plastic strain too.)
• Ceramic-oxide thermal layers, e.g. on gas turbine engines:

• ceramic coating ZrO2-based (lower Tr)
• metal blade (NixCo1-x)CrAlY (higher Tm)
• Failure by delamination without a good design of composite, i.e.

compatibility maintained.
30
Summary
• Composites are classified according to:
-- the matrix material (CMC, MMC, PMC)
-- the reinforcement geometry (particles, fibers, layers).
• Composites enhance matrix properties:
-- MMC: enhance sy, TS, creep performance
-- CMC: enhance Kc
-- PMC: enhance E, sy, TS, creep performance
• Particulate-reinforced:
-- Elastic modulus can be estimated.
-- Properties are isotropic.
• Fiber-reinforced:
-- Elastic modulus and TS can be estimated along fiber dir.
-- Properties can be isotropic or anisotropic.
• Structural:
-- Based on build-up of sandwiches in layered form.
31

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Chapter 15: Composites: Many Engineering Components Are Composites

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Chapter 15: Composites

Many engineering components are composites

Adapted from Fig. 16.4,

Adapted from Fig. 16.5,

• Application to other properties:

From F.L. Matthews and R.L.

concentration size shape

Volume fraction Ec = ∑α =1,N Eα V%α

For Elastic case: σ c = ε c Ec = ε m EmV% % % %

Composite Property: Pc = ∑α =1,N PαV%α * like law of mixtures

Properties include: elastic moduli, density, heat capacity,

Without de-bonding, loads are equal, therefore, strains must add, so

Properties include: elastic moduli, density, heat capacity,

Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre

What is Elastic Modulus?

Ec = V˜ m E m + V˜ fE f=(1−V˜ f)Em +V˜ fEf≈V˜ fEf

* Stiffness of composite under isostrain is dominated by fibers.

Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre

What is Elastic Modulus? 1 V

* Elastic modulus of composite under isoload condition strongly

•Particle reinforcements usually fall in between two extremes.

Are these isostrain or isoload?

What are some real life examples?

3" 4" 6"

• welded tubular composite

If not elastic, then composite fails, due to permanent deformation! Hence

F = FA + FB = A rod (σ A + σB )= A rod (E A εA + E B εB )= A rod εrod (E A + E B )

Adapted from Fig.15.7

Poorer fiber efficiency Better fiber efficiency

• Estimate of Ec and TS: σ fd

-- Elastic modulus in fiber direction:

Gluing together these composite layers

Case I: Elam=(2/3)(150.5 GPa) + (1/3)(7.1 GPa) = 102.7 GPa

Case II: Elam=(1/3)(150.5 GPa) + (2/3)(7.1 GPa) = 54.9 GPa

3 Conditions required: consider top and bottom before laminated

• When glued together displacements have to be same!

Equilibrium: Fy = 0 = (ybot tbot + ytop ttop)L. (t = thickness)

As stress is applied, compatibility can be maintained, depending

Elastic constants are different for different symmetry laminates.

Want compressive stresses at end of

Apply in-pane Tensile Stress

• Depending on placement of load and the orientation of fibers internal

• Examples of orientations of laminated sheets that provided

• The stacking of composite sheets and their angular orientation can be

• Material with most contraction (least) has positive (negative) residual

• Ceramic-oxide thermal layers, e.g. on gas turbine engines:

• Failure by delamination without a good design of composite, i.e.

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