Professional Documents
Culture Documents
COMPOSITE MATERIALS
Anadolu University
MATERIALS
Anadolu University
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?
Anadolu University
Composite Materials
Recommended Texts Strong Solids (Third Ed.) A. Kelly and N.H. MacMillan, Oxford Science Publications Introduction to composites. D. Hull, Cambridge University Press Introduction to Metal Matrix Composites. T.W. Clyne & P.J. Withers, Cambridge University Press
Anadolu University
COMPOSITES
The word composites has a modern ring!!! But the idea is almost older than the wheel In ancient world, straw and horse hair was used to reinforce mud bricks in 3000BC Paper, wood, bone, muscle and concrete are composite materials and all natural But, the composite industry is very new It has grown very fast in the last 50 years Teamwork and Synergy in Materials
Anadolu University
COMPOSITES
The composite idea is that two or more distincly different materials combine together to form a new material which possesses properties that are superior to the properties of the individual components The word COMPOSITE means that a materials system composed of two or more micro- or macro constituents that differ in form and chemical composition and which are essentially insoluble in each other. The constituents retain their identities, i.e.., they do not dissolve or merge into each other, although they act in concert. Normally, the components can be physically identified and exhibit an interface between each other. Alloys are not composite materials Concrete, wood are examples for composites
Anadolu University Materials Science & Engineering
Advantages
High strength and stiffness Low weight ratio Resistance against enviroment and chemicals Material can be designed in addition to the structure
Anadolu University
COMPOSITES
Many of modern technologies require materials with unusual combinations of properties that cannot be met by metals, ceramics or polymers This is especially true for aerospace, underwater and transport applications E.g., aircraft engineers are searching for materials that have low densities, are strong, abrasion and impact resistance and are not easily corroded Difficult to expect one material to meet all these properties E.g., strong materials are relatively dense
Anadolu University Materials Science & Engineering
http://www.aeat.co.uk/ndt/qtnews/nov96/a330.gif
COMPOSITES
Many composite materials are composed of just two phases; one is termed the matrix, which is continuous and surrounds the other phase often called the dispersed phase The properties of composites are a function of the properties of the constituent phases Their relative amounts And the geometry of the dispersed phase i.e., shape of the particles Particle size, distribution and orientation of the dispersed phase
Anadolu University Materials Science & Engineering
TERMINOLOGY/CLASSIFICATION
Composites:
--Multiphase material w/significant proportions of ea. phase.
woven fibers
Matrix:
--The continuous phase --Purpose is to:
transfer stress to other phases protect phases from environment
0.5mm
cross section view
Dispersed phase:
--Purpose: enhance matrix properties.
MMC: increase y, TS, creep resist. CMC: increase Kc PMC: increase E, y, TS, creep resist.
0.5mm
D. Hull and T.W. Clyne, An Materials, 1996
TERMINOLOGY/CLASSIFICATION
http://www.netcomposites.com/education.asp?sequence=3
Anadolu University Materials Science & Engineering
COMPOSITE BENEFITS
CMCs: Increased toughness
Force
particle-reinf
PMCs: Increased E/
ceramics
fiber-reinf un-reinf
6061 Al
10-8
Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp. 139-146, 1984. Used with permission.
10
COMPOSITES
Fiber reinforced
Continous (aligned) Discontinous (short) Aligned
Particulate reinforced
Large particles
Disper. Strengthened
Structural
Laminates Sandwich Panels
Rand. oriented
Anadolu University Materials Science & Engineering
Methods of reinforcing
Schematic illustration of methods of reinforcing plastics (matrix) with (a) particles, and (b) short or long fibers or flakes. The four layers of continuous fibers in illustration (c) are assembled into a laminate structure.
Particulate
small particles that impede dislocation movement (in metal composites) and strengthens the matrix For sizes > 1 m, strength of particle involves in load sharing with matrix
Flakes
flat platelet form
Anadolu University Materials Science & Engineering
COMPOSITES
Fiber
Whisker
Particulate
Laminate
Anadolu University
Steel: density (Fe) = 7.87 g/cc; TS=0.380 GPa; Modulus=207 GPa Al: density=2.71 g/cc; TS=0.035 GPa; Modulus=69 GPa
Anadolu University Materials Science & Engineering
Anadolu University
FIBER STRENGTH
Fibers - Glass
Most widely used fiber Uses: piping, tanks, boats, sporting goods Advantages
low cost Corrosion resistance Low cost relative to other composites:
Disadvantages
Relatively low strength High elongation Moderate strength and weight
Types:
E-Glass - electrical, cheaper S-Glass - high strength
Anadolu University
Examples
Armor, protective clothing, industrial, sporting goods
Advantages:
higher strength and lighter than glass More ductile than carbon
Anadolu University
Fibers - Carbon
2nd most widely used fiber Examples
aerospace, sporting goods
Advantages
high stiffness and strength Low density Intermediate cost Properties:
Standard modulus: 207-240 Gpa Intermediate modulus: 240-340 GPa High modulus: 340-960 GPa Diameter: 5-8 microns, smaller than human hair
Fibers grouped into tows or yarns of 2-12k fibers
Anadolu University Materials Science & Engineering
Fibers - Carbon
Types of carbon fiber
vary in strength with processing Trade-off between strength and modulus
Intermediate modulus
PAN (Polyacrylonitrile)
fiber precursor heated and stretched to align structure and remove non-carbon material
High modulus
made from petroleum pitch precursor at lower cost much lower strength
Anadolu University
Fibers - Others
Boron High stiffness, very high cost Large diameter - 200 microns Good compressive strength Polyethylene - trade name: Spectra fiber Textile industry High strength Extremely light weight Low range of temperature usage Ceramic Fibers (and matrices) Very high temp. applications (e.g. engine components) Silicon carbide fiber - in whisker form. Ceramic matrix so temp. resistance is not compromised Infrequent use
Anadolu University Materials Science & Engineering
Types of Composites
Matrix phase/Reinforceme nt Phase Metal Metal Ceramic Polymer Powder metallurgy parts combining immiscible metals Cermets, TiC, TiCN Cemented carbides used in tools Fiber-reinforced metals Cermets (ceramicmetal composite) SiC reinforced Al2O3 Tool materials Brake pads
Ceramic
Fiberglass
Polymer
Kevlar fibers in an epoxy matrix Fiber reinforced metals Auto parts aerospace Rubber with carbon (tires) Boron, Carbon reinforced plastics
MMCs
Metal Matrix Composites
CMCs
Ceramic Matrix Comps.
PMCs
Polymer Matrix Comps
Types of Composites
The cheapest of all composites are the particulate composites e.g., aggregate+cement concrete & the concrete is cheaper than the cement itself Polymers can be filled with sand or glass particles, increasing the stiffness and wear resistance and often reducing the price Hard metal-tungsten carbide particles in cobalt is the basis of the heavy-duty cutting tool industry
Anadolu University Materials Science & Engineering
Fiber-reinforced
Structural
particles: cementite (Fe3C) (brittle) particles: WC (brittle, hard)
Adapted from Callister 6e. (Fig. is copyright United States Steel Corporation, 1971.)
Vm: 10-15vol%!
Adapted from Callister 6e. (Fig. is courtesy Carboloy Systems, Department, General Electric Company.) Adapted from Callister 6e. (Fig. is courtesy Goodyear Tire and Rubber Company.)
(compliant)
o Cemented carbides - Particulate composites containing hard ceramic particles bonded with a soft metallic matrix. o Electrical Contacts - Materials used for electrical contacts in switches and relays must have a good combination of wear resistance and electrical conductivity. o Polymers - Many engineering polymers that contain fillers and extenders are particulate composites.
(Cu)
(W)
CONCRETE (COMPOSITES )
Concrete is a common large-particle composite in which both matrix and dispersed phases are ceramic materials An aggregate of particles that are bound together in a solid body by some type of binding medium, i.e., cement
Anadolu University
CONCRETE (COMPOSITES )
Anadolu University
Microstructure of tungsten carbide20% cobalt-cemented carbide (1300). (From Metals Handbook, Vol. 7, 8th Ed., American Society for Metals, 1972.)
Microstructure of an aluminum casting alloy reinforced with silicon carbide particles. In this case, the reinforcing particles have segregated to interdendritic regions of the casting ( 125). (Courtesy of David Kennedy, Lester B. Knight Cost Metals Inc.)
DISPERSION-STRENGTHENED COMPOSITES A special group of dispersion-strengthened nanocomposite materials containing particles 10 to 250 nm in diameter is classified as particulate composites. Dispersoids - Tiny oxide particles formed in a metal matrix that interfere with dislocation movement and provide strengthening, even at elevated temperatures.
Anadolu University
DISPERSION-STRENGTHENED COMPOSITES
Electron micrograph of TD-nickel. The dispersed ThO2 particles have a diameter of 300 nm or less. (From Oxide Dispersion Strengthening, p. 714, Gordon and Breach, 1968. AIME.)
DISPERSION-STRENGTHENED COMPOSITES
Anadolu University
Anadolu University
Anadolu University
Examples:
2m
Structural
fracture surface
From F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, 2000.
Structural
C fibers: very stiff very strong C matrix: less stiff view onto plane less strong fibers lie in plane
(a)
Other variations:
--Discontinuous, random 3D --Discontinuous, 1D
Adapted from F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science,
Anadolu University
Anadolu University
Anadolu University
Anadolu University
Two failure modes in ceramic-ceramic composites: (a) Extensive pull-out of SiC fibers in a glass matrix provides good composite toughness (x20). (From Metals Handbook, American Society for Metals, Vol. 9, 9th Ed., 1985.) (b) (b) Bridging of some fibers across a crack enhances the toughness of a ceramic-matrix composite (unknown magnification). ( From Journal of Metals, May 1991.)
(a) Cross-section of a tennis racket, showing graphite and aramid (Kevlar) reinforcing fibers. Source: J. Dvorak, Mercury Marine Corporation, and F. Garrett, Wilson Sporting Goods Co. (b) (b) Cross-section of boron fiber-reinforced composite material.
Source: NASA.
(a) Fracture surface of glass-fiber reinforced epoxy composite. The fibers are 10 m (400 in.) in diameter and have random orientation. (b) Fracture surface of a graphite-fiber reinforced epoxy composite. The fibers, 9 m-11 m in diameter, are in bundles and are all aligned in the same direction. Source: L. J. Broutman.
The tensile strength of glass-reinforced polyester as a function of fiber content and fiber direction in the matrix. Source: R. M. Ogorkiewicz, The Engineering Properties of Plastics. Oxford: Oxford University Press, 1977.
Anadolu University
COMPOSITES
But high stiffness is not always what you want Cushions, packaging and crash padding require materials with moduli lower than those of any solid This can be done with foams-composites of a solid and a gas Many natural materials are cellular: wood & bone Cellular materials permit an optimisation of stiffness, strength & energy absorption These natural & man-made foams or cellular materials are widely used as packaging, padding and insulator materials
Anadolu University Materials Science & Engineering
Structural
Sandwich panels
-- low density, honeycomb core -- benefit: small weight, large bending stiffness
face sheet adhesive layer honeycomb
Adapted from Fig. 16.17, Callister 6e. (Fig. 16.17 is from Engineered Materials Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.
WOOD (COMPOSITES )
Wood consists of strong & flexible cellulose fibers surrounded and held together by a stiffer material called lignin
Anadolu University
WOOD (COMPOSITES )
Anadolu University
CELLULAR (COMPOSITES )
Anadolu University
(a) plywood is a laminar composite of layers of wood veneer, (b) fiberglass is a fiber-reinforced composite containing stiff, strong glass fibers in a softer polymer matrix ( 175), and (c) concrete is a particulate composite containing coarse sand or gravel in a cement matrix (reduced 50%).
Matrix Materials
Functions of the matrix
Transmit force between fibers arrest cracks from spreading between fibers
do not carry most of the load
Demands on matrix
Interlaminar shear strength Toughness Moisture/environmental resistance Temperature properties Cost
Materials Science & Engineering
Anadolu University
Matrix Materials
Every type of composite has a different purpose to be produced Polymers have a low stiffness and are ductile Ceramics & glasses are stiff and strong, but are catastrophically brittle So in fiber reinforced polymer composites, we exploit the great strength of the ceramic while avoiding the catastrophe: the brittle failure of fibres leads to a progressive not a sudden failure Fracture toughness will also increase
Anadolu University Materials Science & Engineering
Anadolu University
Matrices-polymeric
Thermosets
cure by chemical reaction Irreversible Examples
Polyester, vinylester
Most common, lower cost, solvent resistance
Epoxy resins
Superior performance, relatively costly
Anadolu University
Matrices-thermoplastics
Formed by heating to elevated temperature at which softening occurs
Reversible reaction Can be reformed and/or repaired - not common Limited in temperature range to 150C
Examples
Polypropylene
with nylon or glass can be injected-- inexpensive
Soften layers of combined fiber and resin and place in a mold -- higher costs
Anadolu University
Anadolu University
Anadolu University
Specific tensile strength (tensile strength-to-density ratio) and specific tensile modulus (modulus of elasticity-to-density ratio) for various fibers used in reinforced plastics. Note the wide range of specific strengths and stiffnesses available.
Cross-section of a composite sailboard, an example of advanced materials construction. Source: K. Easterling, Tomorrows Materials (2d ed.), p. 133. Institute of Metals, 1990.
Matrices-others
Metal Matrix Composites - higher temperature
e.g., Aluminum with boron or carbon fibers
Anadolu University
Anadolu University
Anadolu University
Anadolu University
Anadolu University
Boron
Alumina
Anadolu University
Anadolu University
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.
APPLICATIONS OF COMPOSITES In designing transportation systems, weight is as important as strength So, they are used in car, aircraft, train & etc. In designing sport equipment, weight is more important than price So, the composites are used for all sorts of sports equipment
Anadolu University
MANUFACTURING FIBERS & 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 fiberreinforced composites in which continuous fibers are wrapped around a form or mandrel. Pultrusion: A method for producing composites containing mats or continuous fibers.
Anadolu University Materials Science & Engineering
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
A scanning electron micrograph of a carbon tow containing many individual carbon filaments (x200).
Anadolu University Materials Science & Engineering
The effect of heat-treatment temperature on the strength and modulus of elasticity of carbon fibers.
PRODUCTION OF COMPOSITES Fibres run through liquid epoxy with a suitable binder Cover it with backing paper Weave the fibers into different forms Then put the layers on top of each other Finally, layers are pressure bonded to each other Other composites production are very similar to Metal or Ceramic production Fiber reinforced composites are produced with special way
Anadolu University Materials Science & Engineering
PRODUCTION OF COMPOSITES
Anadolu University
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Production of fiber tapes by encasing fibers between metal cover sheets by diffusion bonding.
Photomicrographs of two fiber-reinforced composites: (a) In Borsic fiber-reinforced aluminum, the fibers are composed of a thick layer of boron deposited on a small-diameter tungsten filament ( 1000). ( From Metals Handbook, American Society for Metals ) (b) In this microstructure of a ceramic-fiberceramic-matrix composite, SiC fibers are used to reinforce a Si3N4 matrix. The SiC fiber is vapor-deposited on a small carbon precursor filament ( 125). (Courtesy of Dr. R.T. Bhatt, NASA Lewis Research Center.)
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Producing composite shapes in dies by (a) hand lay-up, (b) pressure bag molding, and (c) matched die molding.
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Anadolu University
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Techniques for producing laminar composites: (a) roll bonding, (b) explosive bonding, (c) coextrusion, and (d) brazing.
Anadolu University Materials Science & Engineering
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
In the corrugation method for producing a honeycomb core, the material (such as aluminum) is corrugated between two rolls. The corrugated sheets are joined together with adhesive and then cut to the desired thickness.
Anadolu University Materials Science & Engineering
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
Schematic diagram of an aramid-aluminum laminate, Arall, which has potential for aerospace applications.
Anadolu University Materials Science & Engineering
2003 Brooks/Cole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.
(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.
Anadolu University
PROPERTY
Static Properties
Stiffness Longitudinal Strain Transverse Strain Notch Sensitivity Environmental Sensitivity
FIBER-REINFORCED EPOXY
Linear when loaded in the fiber direction. Non-linear when loading the matrix (eg., shear). Typical fiber failure strains of approx. 2%. Weak matrix so add transverse reinforcement. Low for (static) strength. Good for fatigue-best for blades. Resin-dominated properties susceptible to elevated temperatures and/or humidity.
METALS
Linear to yield point, then nonlinear in the plastic region. Typical failure strains of approx. 1%. Strong (isotropic). Good for (static) strength. Low for fatigue. Relatively insensitive.
Durability
(Fatigue) Highly resistant. Moderately resistant.
Damage Tolerance
Impact Sensitivity Damage Growth Fracture Strength Impact causes resin cracking or fiber fracture. Slow damage growth of delaminations at typical design strains. Relatively low compared to ductile materials. Not a consideration. Metals plastically deform. Continuous crack growth at design strains. Relatively high for ductile materials.
Physical Properties
Density Thermal Expansion Poissons Ratio Conducivity Thermal Electrical Low. Depends upon layup. Fiber ;- low, Resin;- high. Depends upon layup. Low, depends upon layup. Low. Carbon;-conductive, F/G/Kevlar/Quartz;-non-conductive. High. High;-Isotropic. Not direction sensitive. High. High. High.
MICROSTRUCTURE OF A COMPOSITE
Scanning electron micrograph of the fracture surface of a silver-copper alloy reinforced with carbon fibers. Poor bonding causes much of the fracture surface to follow the interface between the metal matrix and the carbon tows ( 3000). (From Metals Handbook, American Society for Metals)
IMPORTANT NOTE Composite properties are less than that of the fiber because of dilution by the matrix and the need to orient fibers in different directions.
Composites are generally anisotropic materials Anisotropy countered by stacking together differently oriented laminae to form laminates
Anadolu University
SUMMARY
Composites are classified according to:
-- the matrix material (CMC, MMC, PMC) -- the reinforcement geometry (particles, fibers, layers).
-- MMC: enhance y, TS, creep performance -- CMC: enhance Kc -- PMC: enhance E, y, 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.
Anadolu University Materials Science & Engineering