COMPOSITE MATERIALS

AE 537

Lecture 2
 TYPES OF MATRICES

Polymers (pmc)
Metals (mmc)
Ceramics (cmc)
Carbon-Carbon Composites
 POLYMER MATRIX COMPOSITES

•What are the most common advanced polymer

composites?
Graphite/Epoxy
Kevlar/Epoxy
Boron/Epoxy

The reasons why they are the most common composites

include their low cost, high strength, and simple
manufacturing principles
 POLYMER MATRIX COMPOSITES

• What are the drawbacks of polymer matrix

composites?
Low operating temperatures
High CTE and CMEs
( Coefficients of thermal and moisture expansion)
Low elastic properties in certain directions
 TA BL E 1 . 4 . T Y P I C A L ME C H A N I C A L P R O P E RT I E S O F
P O LY ME R MAT R I X C O MP O S I T E S A N D MO N O L I T H I C
MAT E R I A L S

Property Units Graphite Glass/ Steel Aluminum

/Epoxy Epoxy
Specific Gravity 1.6 1.8 7.8 2.6

Young’s modulus Msi 26.25 5.598 30.0 10.0

Ultimate Tensile Strength Ksi 217.6 154.0 94.0 40.0

Coefficient of Thermal Expansion in/in/F 0.01111 4.778 6.5 12.8

COMPARATIVE STIFFNESS OF PMCS AND METALS
HOW TO MAKE A PMC
PREPREG BORON/EPOXY
AUTOCLAVE LAMINATION
FILAMENT WINDING
 COMMON PMC FIBERS & MATRICES

• Fibers
• Graphite
• Glass
• Kevlar
• Matrices
• Epoxy
• Phenolic
• Polyester
 GLASS FIBER TYPES

• E-glass (fiberglass) - electrical applications

• S-glass - Strength applications
• C-glass - Corrosion resistant
• D-glass - Low dielectric applications
• A-glass - Appearance applications
• AR-glass - Alkali resistant
C O M PA R I S O N O F R E S I N S
 APPLICATION OF POLYMER MATRIX COMPOSITES

A strong, ultra light leg prosthesis of graphite/epoxy help athletes

compete at the highest levels.
EVERYBODY SKIING USA
FIGHTER JETS
SNOW SKIS
I-BEAM
PRESSURE VESSELS
 METAL MATRIX COMPOSITES

• What are metal-matrix composites?

Metal matrix composites have a metal matrix.

Examples include silicon carbide fibers in

aluminum, graphite fibers in aluminum.
 ADVANTAGES OF MMCS

• Higher specific strength and modulus over

metals.
• Lower coefficients of thermal expansion than
metals by reinforcing with graphite.
• Maintenance of high strength properties at
high temperatures.
 TYPICAL MECHANICAL PROPERTIES OF
METAL MATRIX COMPOSITES

Property Units SiC/ Graphite/ Steel Aluminum

Aluminum Aluminum
Specific Gravity 2.6 2.2 7.8 2.6

Young’s modulus Msi 17 18 30 10

Ultimate Tensile Strength Ksi 175 65 94 34

Coefficient of Thermal Expansion in/in/F 6.9 10 6.5 12.8

 Foil

SCHEMATIC OF DIFFUSION Fiber Mat

BONDING (a)
Foil

Stack
Consolidate

(c)
(b)

(d)

Heat and Pressure

Clean and
(e)
Trim + NDE

Secondary Fabrication (f)

 STEP 0: CUTTING THE SHAPE

STEP 2: CUT TO SHAPE

 STEP 1: APPLY ALUMINUM FOIL

STEP 1: APPLY ALUMINUM FOIL

 STEP 3: LAY UP DESIRED PLIES

STEP 3: LAY UP DESIRED PLIES

 STEP 4:VACUUM THE SPECIMEN

STEP 4:

TO VACUUM
VACUUME

VACUUM
ENCAPSULATE
STEP5: HEAT TO FABRICATION TEMPERATURE

STEP 5: HEAT TO FABRICATION TEMPERATURE

HEAT

HEAT
STEP 6: APPLY PRESSURE AND HOLD FOR
CONSOLIDATION CYCLE

STEP 6: APPLY PRESSURE AND HOLD FOR CONSOLIDATION CYCLE

STEP 7: COOL, REMOVE AND CLEAN PART

STEP 7: COOL, REMOVE AND CLEAN PART

SILICON CARBIDE/ ALUMINUM COMPOSITE
APPLICATION OF MMCS
APPLICATION OF MMCS
 CERAMIC MATRIX COMPOSITES

What are ceramic matrix composites?

Ceramic matrix composites have matrices of
alumina, calcium alumino silicate (CAS),
lithium alumino silicate (LAS). Examples
include Silicon Carbide/CAS and Carbon/LAS.
 ADVANTAGES OF CMCS

High strength, hardness and high service

temperatures
Chemically stable
Low Density
 TA B L E 1 . 1 3 T Y P I C A L M E C H A N I C A L P R O P E RT I E S O F S O M E
C E R A M I C M AT R I X C O M P O S I T E S

Property Units SiC/LAS SiC/CAS Steel Aluminum

Specific Gravity 2.1 2.5 7.8 2.6

Young’s modulus Msi 13 17.55 30.0 10.0

Ultimate Tensile Strength Ksi 72 58.0 94.0 34.0

Coefficient of Thermal Expansion in/in/F 2 2.5 6.5 12.8

MANUFACTURING OF CERAMIC MATRIX
COMPOSITES - SLURRY INFILTRATION
Glass Impregnated
Fiber Tape

Fibers
Glass Slurry Tank

Stack of Glass Impregnated

Binder Burnout Fiber Tapes
500oC

Pressure

Hot Pressing Fiber/Glass Composite

800 - 925oC
 APPLICATION OF CMCS

Applications that need hardness and high temperatures

such as cutting tools, some future aircraft engines
 CARBON-CARBON COMPOSITES

• What are carbon-carbon composites?

Carbon - Carbon composites have carbon

fibers in carbon matrix.
 ADVANTAGES OF CARBON-CARBON
COMPOSITES

• Gradual failure
• Withstand high temperatures
• Low creep at high temperatures
• Low density
• High thermal conductivity
• Low and tailorable (‫ )متكيف‬coefficient of thermal
expansion
 ADVANTAGES OF CARBON-CARBON
COMPOSITES

• Good strength to weight ratio

• High modulus, thermal conductivity, and electrical
conductivity
• Good thermal shock resistance, abrasion (‫ )كشط‬resistance, and
fracture toughness
• Excellent high temperature durability in inert or vacuum
environment
• Good corrosion resistance
 TABLE 1.14 TYPICAL MECHANICAL PROPERTIES
OF CARBON-CARBON MATRIX COMPOSITES

Property Units C-C Steel Aluminum

Specific Gravity 1.68 7.8 2.6

Young’s modulus Msi 1.95 30 10

Ultimate Tensile Strength Ksi 5.180 94 34

Coefficient of Thermal Expansion in/in/F 1.11 6.5 12.8

 APPLICATIONS OF C-C COMPOSITES

• Space Shuttle Nose Cones

• Re-entry temperature of 3092 K
• Aircraft Brakes
• Saves 450 kgs of mass
• 2-4 times durability vs. steel
• 2.5 times specific heat of steel