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ISSUES TO ADDRESS...
What are the classes and types of composites?
What are the advantages of using composite
materials?
How do we predict the stiffness and strength of the
various types of composites?
Chapter 15 - 1
Chapter 15 - 2
1
Composite
Combination of two or more individual
materials
Synergetic Effect!!
Chapter 15 - 3
Terminology/Classification
Composite:
-- Multiphase material that is artificially
made.
Phase types:
-- Matrix - is continuous
-- Dispersed - is discontinuous and
surrounded by matrix
Affected factors
- Concentration
- Size
- Shape
- Distribution
- Orientation
Chapter 15 - 4
2
Terminology/Classification
Matrix phase:
-- Purposes are to:
woven
- transfer stress to dispersed phase
fibers
- protect dispersed phase from
environment
-- Types: MMC, CMC, PMC
Chapter 15 - 5
Classification of Composites
A classification scheme for the various composite types
discussed in this chapter.
Chapter 15 - 6
3
Classification: Particle-Reinforced (i)
Particle-reinforced Fiber-reinforced Structural
Examples:
- Spheroidite matrix: particles: Particle size
steel ferrite () cementite ~ <10~100nm
(ductile) (Fe C) Mostly
3
(brittle) particle(hard),
60 m matrix(soft)
- WC/Co matrix: particles: Enhanced toughness,
cemented cobalt WC Withstanding high
(ductile, (brittle, Temp.
carbide tough)
: hard)
600 m
Cheap carbon black(CB)
- Automobile matrix: particles: Increase TS,
tire rubber rubber carbon toughness, tear &
(compliant) black abrasion resistance
; 15~30% CB
(stiff)
0.75 m Chapter 15 - 7
4
Classification: Particle-Reinforced (iii)
Particle-reinforced Fiber-reinforced Structural
Elastic modulus, Ec, of composites:
-- two rule of mixture extremes:
E: elastic modulus
upper limit: Ec = Vm Em + Vp Ep V: volume fraction
E(GPa) c, m, p: comp., matrix, particulate phase
Data: 350
lower limit: Modulus of elasticity versus
Cu matrix 300
1 Vm Vp volume percent tungsten for
w/tungsten 250 = + a composite of tungsten
particles 200 Ec Em Ep particles dispersed within a
copper matrix. Upper and
150 lower bounds are according
to Equations 15.1 and 15.2;
0 20 40 60 80 10 0 vol% tungsten
experimental data points are
(Cu) (W) included.
Chapter 15 - 10
5
Classification: Fiber-Reinforced (ii)
Particle-reinforced Fiber-reinforced Structural
Fiber Types
Whiskers - thin single crystals - large length to diameter ratios
graphite, silicon nitride, silicon carbide
high crystal perfection extremely strong, strongest known
very expensive and difficult to disperse
Fibers
polycrystalline or amorphous
generally polymers or ceramics
Ex: alumina, aramid, E-glass, boron, UHMWPE
Wires
metals steel, molybdenum, tungsten
Chapter 15 - 11
Fiber Alignment
Schematic representations of (a) continuous and aligned, (b)
discontinous and aligned, and (c) discontinuous and randomly
oriented fiber reinforced composites..
(a) (b) (c)
6
Classification: Fiber-Reinforced (iii)
Particle-reinforced Fiber-reinforced Structural
(a) fracture
surface
2 m
Chapter 15 - 13
Chapter 15 - 14
7
Classification: Fiber-Reinforced (v)
Particle-reinforced Fiber-reinforced Structural
Critical fiber length(lc) for effective stiffening & strengthening:
fiber ultimate
fiber diameter
tensile strength
shear strength of
fiber-matrix interface
Composite Stiffness:
Longitudinal Loading
& Aligned
/ = E,
c = composite
f = fiber
m = matrix
Chapter 15 - 16
8
Composite Stiffness:
Transverse Loading
For continuous and aligned fiber,
In transverse loading the fibers carry less of the load
Strain or Deformation of the entire composite
c= mVm + fVf and c = m = f =
isostress
1 V V
m f where =/E
Ect E m Ef
c = composite Ect = transverse modulus
f = fiber
m = matrix
EmEf
Ect
VmEf Vf Em
Chapter 15 - 17
Composite Stiffness
Particle-reinforced Fiber-reinforced Structural
Chapter 15 - 18
9
Composite Strength
Particle-reinforced Fiber-reinforced Structural
Composite Strength
Characteristics of Several fiber-reinforcement Materials
Chapter 15 - 20
10
Polymer Matrix Composite
Glass Fiber-Reinforced Polymer (GFRP)
Fiberglass (or E-glass) consisting of glass fibers
Fiber diameter: 3~20 m
Advantages
Easily drawn into high-strength fiber from molten state
Adaptable to many used manufacturing methods
Very high specific strength
Chemical inertness efficient to corrosive environment.
Limitations
Not very stiff for airplane and bridge
Service temp below 200C
Applications
Automotive and marine bodies, plastic pipes, storage
containers, and industrial flooring
Chapter 15 - 21
11
Polymer Matrix Composite
Aramid Fiber-Reinforced Polymer (AFRP)
High modulus and high strength material in early 1970s
Main constituent; Poly(paraphenylene terephthalamide)
Major trade names : KelvarTM, NormexTM
Kelvar: classified with numbers Kelvar 29, 49, 149
Higher longitudinal tensile strength and tensile moduli
Relatively weak in compression
toughness, impact resistance, and resistance to creep
& fatigue failure
Thermoplastic but resistant to combustion, relatively ductile
Stable to high T. for -200 ~ 200C
Applications
Bullet-proof vests and armor, sporting goods, tires, ropes, missile
cases, pressure vessels and clutch linings and gaskets
Chapter 15 - 23
Chapter 15 - 24
12
Carbon-Carbon Composite
Reinforcement and matrix are carbon.
Relatively new and expensive because of pyrolysis &
high temperature treatment
High tensile moduli and strength even in excess of
2000C, resistance to creep and relatively large
fracture toughness
Low thermal coefficient and high thermal conductivity
Combined with mechanical strength beneficial to thermal shock
Main drawback: high temperature oxidation
Applications
Rocket motor, for friction material in aircraft and automobile, for hot-
pressing molds, components in turbine engines
Chapter 15 - 25
Chapter 15 - 26
13
Composite Production Methods (i)
Pultrusion
Continuous fibers pulled through resin tank, then
to preforming and curing dies
Reinforcements: glass, carbon, aramid
http://www.youtube.com/
watch?v=9tlQn5_cko0 Chapter 15 - 27
Chapter 15 - 28
14
Classification: Structural
Particle-reinforced Fiber-reinforced Structural
Laminates -
-- stacked and bonded fiber-reinforced sheets
- stacking sequence: e.g., 0/90
- benefit: balanced in-plane stiffness
Sandwich panels
-- honeycomb core between two facing sheets
- benefits: low density, large bending stiffness
face sheet
adhesive layer
honeycomb
Chapter 15 - 29
Composite Benefits
CMCs: Increased toughness PMCs: Increased E/
Force 3 ceramics
particle-reinf 10
E(GPa) 2 PMCs
10
10 metal/
fiber-reinf
1 metal alloys
un-reinf
0.1 polymers
0.01
Bend displacement 0.1 0.3 1 3 10 30
10 -4 Density, [mg/m3]
ss (s-1) 6061 Al
MMCs: 10 -6
Increased
creep 10 -8 6061 Al
resistance w/SiC
whiskers
10 -10
(MPa)
20 30 50 100 200 Chapter 15 - 30
15
Composite Benefits
Chapter 15 - 31
Composite Benefits
Chapter 15 - 32
16
Summary
Composites types are designated by:
-- the matrix material (CMC, MMC, PMC)
-- the reinforcement (particles, fibers, structural)
Composite property benefits:
-- MMC: enhanced E, , creep performance
-- CMC: enhanced KIc
-- PMC: enhanced E/, y, TS/
Particulate-reinforced:
-- Types: large-particle and dispersion-strengthened
-- Properties are isotropic
Fiber-reinforced:
-- Types: continuous (aligned)
discontinuous (aligned or random)
-- Properties can be isotropic or anisotropic
Structural:
-- Laminates and sandwich panels
Chapter 15 - 33
17