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Composite material
A composite material (also called a composition material or
shortened to composite, which is the common name) is a material made
from two or more constituent materials with significantly different physical
or chemical properties that, when combined, produce a material with
characteristics different from the individual components. The individual
components remain separate and distinct within the finished structure.

The new material may be preferred for many reasons: common examples
include materials which are stronger, lighter, or less expensive when
compared to traditional materials. Composites are formed by
combining materials together to
More recently, researchers have also begun to actively include sensing, form an overall structure with
actuation, computation and communication into composites,[1] which are properties that differ from the sum of
the individual components
known as Robotic Materials.[2]

Typical engineered composite materials include:

Reinforced concrete and masonry

Composite wood such as plywood
Reinforced plastics, such as fibre-reinforced polymer or fiberglass
Ceramic matrix composites (composite ceramic and metal matrices)
Metal matrix composites
and other Advanced composite materials
Composite materials are generally used for buildings, bridges, and A black carbon fibre (used as a
reinforcement component)
structures such as boat hulls, swimming pool panels, racing car bodies,
compared to a human hair
shower stalls, bathtubs, storage tanks, imitation granite and cultured
marble sinks and countertops.

The most advanced examples perform routinely on spacecraft and aircraft in demanding environments.

Contents
History
Examples
Composite Materials
Products
Overview
Constituents
Matrices
Organic
Inorganic
Reinforcements
Fibre
Other reinforcement
Cores
Fabrication methods

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Mold overview
Vacuum bag moulding
Pressure bag moulding
Autoclave moulding
Resin transfer moulding (RTM)
Other fabrication methods
Finishing methods
Tooling
Physical properties
Failure
Testing
See also
References
Further reading
External links

History
The earliest man-made composite materials were straw and mud combined to form bricks for building construction.
Ancient brick-making was documented by Egyptian tomb paintings .

Wattle and daub is one of the oldest man-made composite materials, at over 6000 years old.[3] Concrete is also a
composite material, and is used more than any other man-made material in the world. As of 2006, about 7.5 billion
cubic metres of concrete are made each year—more than one cubic metre for every person on Earth.[4]

Woody plants, both true wood from trees and such plants as palms and bamboo, yield natural composites that
were used prehistorically by mankind and are still used widely in construction and scaffolding.
Plywood 3400 BC[5] by the Ancient Mesopotamians; gluing wood at different angles gives better properties than
natural wood.
Cartonnage layers of linen or papyrus soaked in plaster dates to the First Intermediate Period of Egypt c. 2181–
2055 BC[6] and was used for death masks.
Cob (material) Mud Bricks, or Mud Walls, (using mud (clay) with straw or gravel as a binder) have been used for
thousands of years.
Concrete was described by Vitruvius, writing around 25 BC in his Ten Books on Architecture, distinguished types
of aggregate appropriate for the preparation of lime mortars. For structural mortars, he recommended pozzolana,
which were volcanic sands from the sandlike beds of Pozzuoli brownish-yellow-gray in colour near Naples and
reddish-brown at Rome. Vitruvius specifies a ratio of 1 part lime to 3 parts pozzolana for cements used in
buildings and a 1:2 ratio of lime to pulvis Puteolanus for underwater work, essentially the same ratio mixed today
for concrete used at sea.[7] Natural cement-stones, after burning, produced cements used in concretes from post-
Roman times into the 20th century, with some properties superior to manufactured Portland cement.
Papier-mâché, a composite of paper and glue, has been used for hundreds of years.
The first artificial fibre reinforced plastic was bakelite which dates to 1907, although natural polymers such as
shellac predate it.
One of the most common and familiar composite is fibreglass, in which small glass fibre are embedded within a
polymeric material (normally an epoxy or polyester). The glass fibre is relatively strong and stiff (but also brittle),
whereas the polymer is ductile (but also weak and flexible). Thus the resulting fibreglass is relatively stiff, strong,
flexible, and ductile.

Examples

Composite Materials

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Concrete is the most common artificial composite material of all and

typically consists of loose stones (aggregate) held with a matrix of cement.
Concrete is an inexpensive material, and will not compress or shatter even
under quite a large compressive force.[8] However, concrete cannot survive
tensile loading[9](i.e., if stretched it will quickly break apart). Therefore, to
give concrete the ability to resist being stretched, steel bars, which can
resist high stretching forces, are often added to concrete to form reinforced
concrete.

Fibre-reinforced polymers (FRP)s include carbon-fibre-reinforced Concrete is a mixture of cement and

polymer(CFRP) and glass-reinforced plastic(GRP). If classified by matrix aggregate, giving a robust, strong
material that is very widely used.
then there are thermoplastic composites, short fibre thermoplastics, long
fibre thermoplastics or long fibre-reinforced thermoplastics. There are
numerous thermoset composites, including paper composite panels. Many
advanced thermoset polymer matrix systems usually incorporate aramid
fibre and carbon fibre in an epoxy resin matrix.

Shape memory polymer composites are high-performance composites,

formulated using fibre or fabric reinforcement and shape memory polymer
resin as the matrix. Since a shape memory polymer resin is used as the
matrix, these composites have the ability to be easily manipulated into
various configurations when they are heated above their activation
temperatures and will exhibit high strength and stiffness at lower Plywood is used widely in
temperatures. They can also be reheated and reshaped repeatedly without construction

losing their material properties. These composites are ideal for

applications such as lightweight, rigid, deployable structures; rapid
manufacturing; and dynamic reinforcement.

High strain composites are another type of high-performance composites

that are designed to perform in a high deformation setting and are often
used in deployable systems where structural flexing is advantageous.
Although high strain composites exhibit many similarities to shape
memory polymers, their performance is generally dependent on the fibre
layout as opposed to the resin content of the matrix. Composite sandwich structure panel
used for testing at NASA
Composites can also use metal fibres reinforcing other metals, as in metal
matrix composites (MMC) or ceramic matrix composites (CMC), which
includes bone (hydroxyapatite reinforced with collagen fibres), cermet
(ceramic and metal) and concrete. Ceramic matrix composites are built
primarily for fracture toughness, not for strength. Another class of
composite materials involve woven fabric composite consisting of
longitudinal and transverse laced yarns. Woven fabric composites are
flexible as they are in form of fabric.

Organic matrix/ceramic aggregate composites include asphalt concrete,

polymer concrete, mastic asphalt, mastic roller hybrid, dental composite,
syntactic foam and mother of pearl. Chobham armour is a special type of "Structural Integrity Analysis :
composite armour used in military applications. Composites" (http://www.kokch.kts.r
u/me/t9/SIA_9_Composites.pdf)
Additionally, thermoplastic composite materials can be formulated with (PDF).
specific metal powders resulting in materials with a density range from 2
g/cm³ to 11 g/cm³ (same density as lead). The most common name for this
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type of material is "high gravity compound" (HGC), although "lead replacement" is also used. These materials can be
used in place of traditional materials such as aluminium, stainless steel, brass, bronze, copper, lead, and even tungsten
in weighting, balancing (for example, modifying the centre of gravity of a tennis racquet), vibration damping, and
radiation shielding applications. High density composites are an economically viable option when certain materials
are deemed hazardous and are banned (such as lead) or when secondary operations costs (such as machining,
finishing, or coating) are a factor.

A sandwich-structured composite is a special class of composite material that is fabricated by attaching two thin but
stiff skins to a lightweight but thick core. The core material is normally low strength material, but its higher thickness
provides the sandwich composite with high bending stiffness with overall low density.

Wood is a naturally occurring composite comprising cellulose fibres in a lignin and hemicellulose matrix. Engineered
wood includes a wide variety of different products such as wood fibre board, plywood, oriented strand board, wood
plastic composite (recycled wood fibre in polyethylene matrix), Pykrete (sawdust in ice matrix), Plastic-impregnated
or laminated paper or textiles, Arborite, Formica (plastic) and Micarta. Other engineered laminate composites, such as
Mallite, use a central core of end grain balsa wood, bonded to surface skins of light alloy or GRP. These generate low-
weight, high rigidity materials.

Particulate composites have particle as filler material dispersed in matrix, which may be nonmetal, such as glass,
epoxy. Automobile tire is an example of particulate composite.

Advanced diamond-like carbon (DLC) coated polymer composites have been reported[10] where the coating increases
the surface hydrophobicity, hardness and wear resistance.

Products
Fibre-reinforced composite materials have gained popularity (despite their generally high cost) in high-performance
products that need to be lightweight, yet strong enough to take harsh loading conditions such as aerospace
components (tails, wings, fuselages, propellers), boat and scull hulls, bicycle frames and racing car bodies. Other uses
include fishing rods, storage tanks, swimming pool panels, and baseball bats. The Boeing 787 and Airbus A350
structures including the wings and fuselage are composed largely of composites. Composite materials are also
becoming more common in the realm of orthopedic surgery.And It is the most common hockey stick material.

Carbon composite is a key material in today's launch vehicles and heat shields for the re-entry phase of spacecraft. It is
widely used in solar panel substrates, antenna reflectors and yokes of spacecraft. It is also used in payload adapters,
inter-stage structures and heat shields of launch vehicles. Furthermore, disk brake systems of airplanes and racing
cars are using carbon/carbon material, and the composite material with carbon fibres and silicon carbide matrix has
been introduced in luxury vehicles and sports cars.

In 2006, a fibre-reinforced composite pool panel was introduced for in-ground swimming pools, residential as well as
commercial, as a non-corrosive alternative to galvanized steel.

In 2007, an all-composite military Humvee was introduced by TPI Composites Inc and Armor Holdings Inc, the first
all-composite military vehicle. By using composites the vehicle is lighter, allowing higher payloads. In 2008, carbon
fibre and DuPont Kevlar (five times stronger than steel) were combined with enhanced thermoset resins to make
military transit cases by ECS Composites creating 30-percent lighter cases with high strength.

Pipes and fittings for various purpose like transportation of potable water, fire-fighting, irrigation, seawater,
desalinated water, chemical and industrial waste, and sewage are now manufactured in glass reinforced plastics.

Overview

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Composites are made up of individual materials referred to as constituent

materials. There are two main categories of constituent materials: matrix (binder)
and reinforcement. At least one portion of each type is required. The matrix
material surrounds and supports the reinforcement materials by maintaining their
relative positions. The reinforcements impart their special mechanical and physical
properties to enhance the matrix properties. A synergism produces material
properties unavailable from the individual constituent materials, while the wide
variety of matrix and strengthening materials allows the designer of the product or
structure to choose an optimum combination.

Engineered composite materials must be formed to shape. The matrix material can
be introduced to the reinforcement before or after the reinforcement material is
placed into the mould cavity or onto the mould surface. The matrix material
experiences a melding event, after which the part shape is essentially set.
Depending upon the nature of the matrix material, this melding event can occur in
various ways such as chemical polymerization for a thermoset polymer matrix, or
solidification from the melted state for a thermoplastic polymer matrix composite.

A variety of moulding methods can be used according to the end-item design

requirements. The principal factors impacting the methodology are the natures of
the chosen matrix and reinforcement materials. Another important factor is the
gross quantity of material to be produced. Large quantities can be used to justify
high capital expenditures for rapid and automated manufacturing technology.
Carbon fibre composite
Small production quantities are accommodated with lower capital expenditures but part.
higher labour and tooling costs at a correspondingly slower rate.

Many commercially produced composites use a polymer matrix material often called a resin solution. There are many
different polymers available depending upon the starting raw ingredients. There are several broad categories, each
with numerous variations. The most common are known as polyester, vinyl ester, epoxy, phenolic, polyimide,
polyamide, polypropylene, PEEK, and others. The reinforcement materials are often fibres but also commonly ground
minerals. The various methods described below have been developed to reduce the resin content of the final product,
or the fibre content is increased. As a rule of thumb, lay up results in a product containing 60% resin and 40% fibre,
whereas vacuum infusion gives a final product with 40% resin and 60% fibre content. The strength of the product is
greatly dependent on this ratio.

Martin Hubbe and Lucian A Lucia consider wood to be a natural composite of cellulose fibres in a matrix of
lignin.[11][12]

Constituents

Matrices

Organic
Polymers are common matrices (especially used for fibre reinforced plastics). Road surfaces are often made from
asphalt concrete which uses bitumen as a matrix. Mud (wattle and daub) has seen extensive use. Typically, most
common polymer-based composite materials, including fibreglass, carbon fibre, and Kevlar, include at least two parts,
the substrate and the resin.

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Polyester resin tends to have yellowish tint, and is suitable for most backyard projects. Its weaknesses are that it is UV
sensitive and can tend to degrade over time, and thus generally is also coated to help preserve it. It is often used in the
making of surfboards and for marine applications. Its hardener is a peroxide, often MEKP (methyl ethyl ketone
peroxide). When the peroxide is mixed with the resin, it decomposes to generate free radicals, which initiate the curing
reaction. Hardeners in these systems are commonly called catalysts, but since they do not re-appear unchanged at the
end of the reaction, they do not fit the strictest chemical definition of a catalyst.

Vinylester resin tends to have a purplish to bluish to greenish tint. This resin has lower viscosity than polyester resin,
and is more transparent. This resin is often billed as being fuel resistant, but will melt in contact with gasoline. This
resin tends to be more resistant over time to degradation than polyester resin, and is more flexible. It uses the same
hardeners as polyester resin (at a similar mix ratio) and the cost is approximately the same.

Epoxy resin is almost totally transparent when cured. In the aerospace industry, epoxy is used as a structural matrix
material or as a structural glue.

Shape memory polymer (SMP) resins have varying visual characteristics depending on their formulation. These resins
may be epoxy-based, which can be used for auto body and outdoor equipment repairs; cyanate-ester-based, which are
used in space applications; and acrylate-based, which can be used in very cold temperature applications, such as for
sensors that indicate whether perishable goods have warmed above a certain maximum temperature. These resins are
unique in that their shape can be repeatedly changed by heating above their glass transition temperature (Tg). When
heated, they become flexible and elastic, allowing for easy configuration. Once they are cooled, they will maintain their
new shape. The resins will return to their original shapes when they are reheated above their Tg. The advantage of
shape memory polymer resins is that they can be shaped and reshaped repeatedly without losing their material
properties. These resins can be used in fabricating shape memory composites.

Traditional materials such as glues, muds have traditionally been used as matrices for papier-mâché and adobe.

Inorganic
Cement (concrete), metals, ceramics, and sometimes glasses are employed. Unusual matrices such as ice are sometime
proposed as in pykecrete.

Reinforcements

Fibre
Reinforcement usually adds rigidity and greatly impedes crack propagation. Thin fibres can have very high strength,
and provided they are mechanically well attached to the matrix they can greatly improve the composite's overall
properties.

Fibre-reinforced composite materials can be divided into two main categories normally referred to as short fibre-
reinforced materials and continuous fibre-reinforced materials. Continuous reinforced materials will often constitute a
layered or laminated structure. The woven and continuous fibre styles are typically available in a variety of forms,
being pre-impregnated with the given matrix (resin), dry, uni-directional tapes of various widths, plain weave, harness
satins, braided, and stitched.

The short and long fibres are typically employed in compression moulding and sheet moulding operations. These
come in the form of flakes, chips, and random mate (which can also be made from a continuous fibre laid in random
fashion until the desired thickness of the ply / laminate is achieved).

Common fibres used for reinforcement include glass fibres, carbon fibres, cellulose (wood/paper fibre and straw) and
high strength polymers for example aramid. Silicon carbide fibres are used for some high temperature applications.

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Other reinforcement
Concrete uses aggregate, and reinforced concrete additionally
uses steel bars (rebar) to tension the concrete. Steel mesh or
wires are also used in some glass and plastic products.

Cores
Many composite layup designs also include a co-curing or
post-curing of the prepreg with various other media, such as
honeycomb or foam. This is commonly called a sandwich
structure. This is a more common layup for the manufacture
of radomes, doors, cowlings, or non-structural parts.

Open- and closed-cell-structured foams like

polyvinylchloride, polyurethane, polyethylene or polystyrene
Differences in the way the fibres are laid out give
foams, balsa wood, syntactic foams, and honeycombs are different strengths and ease of manufacture
commonly used core materials. Open- and closed-cell metal
foam can also be used as core materials. Recently, 3D
graphene structures ( also called graphene foam) have also been employed as core structures. A recent review by
Khurram and Xu et al., have provided the summary of the state-of-the-art techniques for fabrication of the 3D
structure of graphene, and the examples of the use of these foam like structures as a core for their respective polymer
composites.[13]

Fabrication methods
Fabrication of composite materials is accomplished by a wide variety of techniques, including:

Advanced fibre placement (Automated fibre placement)

Tailored fibre placement
fibreglass spray lay-up process
Filament winding
Lanxide process
Tufting
Z-pinning
Composite fabrication usually involves wetting, mixing or saturating the reinforcement with the matrix, and then
causing the matrix to bind together (with heat or a chemical reaction) into a rigid structure. The operation is usually
done in an open or closed forming mold, but the order and ways of introducing the ingredients varies considerably.

Mold overview
Within a mold, the reinforcing and matrix materials are combined, compacted, and cured (processed) to undergo a
melding event. After the melding event, the part shape is essentially set, although it can deform under certain process
conditions. For a thermoset polymer matrix material, the melding event is a curing reaction that is initiated by the
application of additional heat or chemical reactivity such as an organic peroxide. For a thermoplastic polymeric matrix
material, the melding event is a solidification from the melted state. For a metal matrix material such as titanium foil,
the melding event is a fusing at high pressure and a temperature near the melting point.

For many moulding methods, it is convenient to refer to one mould piece as a "lower" mould and another mould piece
as an "upper" mould. Lower and upper refer to the different faces of the moulded panel, not the mould's configuration
in space. In this convention, there is always a lower mould, and sometimes an upper mould. Part construction begins

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by applying materials to the lower mould. Lower mould and upper mould are more generalized descriptors than more
common and specific terms such as male side, female side, a-side, b-side, tool side, bowl, hat, mandrel, etc.
Continuous manufacturing uses a different nomenclature.

The moulded product is often referred to as a panel. For certain geometries and material combinations, it can be
referred to as a casting. For certain continuous processes, it can be referred to as a profile.

Vacuum bag moulding

Vacuum bag moulding uses a flexible film to enclose the part and seal it from outside air. Vacuum bag material is
available in a tube shape or a sheet of material. A vacuum is then drawn on the vacuum bag and atmospheric pressure
compresses the part during the cure. When a tube shaped bag is used, the entire part can be enclosed within the bag.
When using sheet bagging materials, the edges of the vacuum bag are sealed against the edges of the mould surface to
enclose the part against an air-tight mould. When bagged in this way, the lower mold is a rigid structure and the upper
surface of the part is formed by the flexible membrane vacuum bag. The flexible membrane can be a reusable silicone
material or an extruded polymer film. After sealing the part inside the vacuum bag, a vacuum is drawn on the part
(and held) during cure. This process can be performed at either ambient or elevated temperature with ambient
atmospheric pressure acting upon the vacuum bag. A vacuum pump is typically used to draw a vacuum. An economical
method of drawing a vacuum is with a venturi vacuum and air compressor.

A vacuum bag is a bag made of strong rubber-coated fabric or a polymer film used to compress the part during cure or
hardening. In some applications the bag encloses the entire material, or in other applications a mold is used to form
one face of the laminate with the bag being a single layer to seal to the outer edge of the mold face. When using a tube
shaped bag, the ends of the bag are sealed and the air is drawn out of the bag through a nipple using a vacuum pump.
As a result, uniform pressure approaching one atmosphere is applied to the surfaces of the object inside the bag,
holding parts together while the adhesive cures. The entire bag may be placed in a temperature-controlled oven, oil
bath or water bath and gently heated to accelerate curing.

Vacuum bagging is widely used in the composites industry as well. Carbon fibre fabric and fibreglass, along with resins
and epoxies are common materials laminated together with a vacuum bag operation.

Woodworking applications

In commercial woodworking facilities, vacuum bags are used to laminate curved and irregular shaped workpieces.

Typically, polyurethane or vinyl materials are used to make the bag. A tube shaped bag is open at both ends. The piece,
or pieces to be glued are placed into the bag and the ends sealed. One method of sealing the open ends of the bag is by
placing a clamp on each end of the bag. A plastic rod is laid across the end of the bag, the bag is then folded over the
rod. A plastic sleeve with an opening in it, is then snapped over the rod. This procedure forms a seal at both ends of the
bag, when the vacuum is ready to be drawn.

A "platen" is sometimes used inside the bag for the piece being glued to lie on. The platen has a series of small slots cut
into it, to allow the air under it to be evacuated. The platen must have rounded edges and corners to prevent the
vacuum from tearing the bag.

When a curved part is to be glued in a vacuum bag, it is important that the pieces being glued be placed over a solidly
built form, or have an air bladder placed under the form. This air bladder has access to "free air" outside the bag. It is
used to create an equal pressure under the form, preventing it from being crushed.[14]

Pressure bag moulding

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This process is related to vacuum bag molding in exactly the same way as it sounds. A solid female mold is used along
with a flexible male mold. The reinforcement is placed inside the female mold with just enough resin to allow the
fabric to stick in place (wet lay up). A measured amount of resin is then liberally brushed indiscriminately into the
mold and the mold is then clamped to a machine that contains the male flexible mold. The flexible male membrane is
then inflated with heated compressed air or possibly steam. The female mold can also be heated. Excess resin is forced
out along with trapped air. This process is extensively used in the production of composite helmets due to the lower
cost of unskilled labor. Cycle times for a helmet bag moulding machine vary from 20 to 45 minutes, but the finished
shells require no further curing if the molds are heated.

Autoclave moulding
A process using a two-sided mould set that forms both surfaces of the panel. On the lower side is a rigid mould and on
the upper side is a flexible membrane made from silicone or an extruded polymer film such as nylon. Reinforcement
materials can be placed manually or robotically. They include continuous fibre forms fashioned into textile
constructions. Most often, they are pre-impregnated with the resin in the form of prepreg fabrics or unidirectional
tapes. In some instances, a resin film is placed upon the lower mould and dry reinforcement is placed above. The
upper mould is installed and vacuum is applied to the mould cavity. The assembly is placed into an autoclave. This
process is generally performed at both elevated pressure and elevated temperature. The use of elevated pressure
facilitates a high fibre volume fraction and low void content for maximum structural efficiency.

Resin transfer moulding (RTM)

RTM is a process using a rigid two-sided mould set that forms both surfaces of the panel. The mould is typically
constructed from aluminum or steel, but composite molds are sometimes used. The two sides fit together to produce a
mould cavity. The distinguishing feature of resin transfer moulding is that the reinforcement materials are placed into
this cavity and the mould set is closed prior to the introduction of matrix material. Resin transfer moulding includes
numerous varieties which differ in the mechanics of how the resin is introduced to the reinforcement in the mould
cavity. These variations include everything from the RTM methods used in out of autoclave composite manufacturing
for high-tech aerospace components to vacuum infusion (for resin infusion see also boat building) to vacuum assisted
resin transfer moulding (VARTM). This process can be performed at either ambient or elevated temperature.

Other fabrication methods

Other types of fabrication include press moulding, transfer moulding, pultrusion moulding, filament winding, casting,
centrifugal casting, continuous casting and slip forming. There are also forming capabilities including CNC filament
winding, vacuum infusion, wet lay-up, compression moulding, and thermoplastic moulding, to name a few. The use of
curing ovens and paint booths is also needed for some projects.

Finishing methods
The finishing of the composite parts is also critical in the final design. Many of these finishes will include rain-erosion
coatings or polyurethane coatings.

Tooling
The mold and mold inserts are referred to as "tooling." The mold/tooling can be constructed from a variety of
materials. Tooling materials include invar, steel, aluminium, reinforced silicone rubber, nickel, and carbon fibre.
Selection of the tooling material is typically based on, but not limited to, the coefficient of thermal expansion, expected
number of cycles, end item tolerance, desired or required surface condition, method of cure, glass transition
temperature of the material being moulded, moulding method, matrix, cost and a variety of other considerations.

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Physical properties
The physical properties of composite materials are generally not isotropic
(independent of direction of applied force) in nature, but they are typically
anisotropic (different depending on the direction of the applied force or
load). For instance, the stiffness of a composite panel will often depend
upon the orientation of the applied forces and/or moments. The strength
of a composite is bounded by two loading conditions as shown in the plot
to the right. If both the fibres and matrix are aligned parallel to the loading
direction, the deformation of both phases will be the same (assuming there
is no delamination at the fibre-matrix interface). This isostrain condition
provides the upper bound for composite strength, and is determined by the Plot of the overall strength of a
rule of mixtures: composite material as a function of
fiber volume fraction limited by the
upper bound (isostrain) and lower
bound (isostress) conditions.

where EC is the effective composite Young’s modulus, and Vi and Ei are the
volume fraction and Young’s moduli, respectively, of the composite phases.

For example, a composite material made up of α and β phases as shown in

the figure to the right under isostrain, the Young's modulus would be as
follows:

where Vα and Vβ are the respective volume fractions of each

phase.
Figure a) shows the isostress
condition where the composite
The lower bound is dictated by the isostress condition, in which the fibres
materials are perpendicular to the
and matrix are oriented perpendicularly to the loading direction: applied force and b) is the isostrain
condition that has the layers parallel
to the force.[15]

Following the example above, if one had a composite material made up of α

and β phases under isostress conditions as shown in the figure to the right, the composition Young's modulus would
be:

The isostrain condition implies that under an applied load, both phases experience the same strain
but will feel different stress. Comparatively, under isostress conditions both phases will feel the
same stress but the strains will differ between each phase. Though composite stiffness is
maximized when fibres are aligned with the loading direction, so is the possibility of fibre tensile
fracture, assuming the tensile strength exceeds that of the matrix. When a fibre has some angle of
misorientation θ, several fracture modes are possible. For small values of θ the stress required to
initiate fracture is increased by a factor of (cos θ)−2 due to the increased cross-sectional area (A cos
θ) of the fibre and reduced force (F/cos θ) experienced by the fibre, leading to a composite tensile
strength of σparallel /cos2 θ where σparallel is the tensile strength of the composite with fibres
aligned parallel with the applied force.

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Intermediate angles of misorientation θ lead to matrix shear failure. Again the cross sectional area is modified but
since shear stress is now the driving force for failure the area of the matrix parallel to the fibres is of interest,
increasing by a factor of 1/sin θ. Similarly, the force parallel to this area again decreases (F/cos θ) leading to a total
tensile strength of τmy /sinθ cosθ where τmy is the matrix shear strength.

Finally, for large values of θ (near π/2) transverse matrix failure is the most likely to occur, since the fibres no longer
carry the majority of the load. Still, the tensile strength will be greater than for the purely perpendicular orientation,
since the force perpendicular to the fibres will decrease by a factor of 1/sin θ and the area decreases by a factor of 1/sin
θ producing a composite tensile strength of σperp /sin2θ where σperp is the tensile strength of the composite with fibres
align perpendicular to the applied force.[16]

The majority of commercial composites are formed with random

dispersion and orientation of the strengthening fibres, in which case the
composite Young’s modulus will fall between the isostrain and isostress
bounds. However, in applications where the strength-to-weight ratio is
engineered to be as high as possible (such as in the aerospace industry),
fibre alignment may be tightly controlled.

Panel stiffness is also dependent on the design of the panel. For instance, The graph depicts the three fracture
modes a composite material may
the fibre reinforcement and matrix used, the method of panel build,
experience depending on the angle
thermoset versus thermoplastic, and type of weave.
of misorientation relative to aligning
fibres parallel to the applied stress.
In contrast to composites, isotropic materials (for example, aluminium or
steel), in standard wrought forms, typically have the same stiffness
regardless of the directional orientation of the applied forces and/or moments. The relationship between
forces/moments and strains/curvatures for an isotropic material can be described with the following material
properties: Young's Modulus, the shear Modulus and the Poisson's ratio, in relatively simple mathematical
relationships. For the anisotropic material, it requires the mathematics of a second order tensor and up to 21 material
property constants. For the special case of orthogonal isotropy, there are three different material property constants
for each of Young's Modulus, Shear Modulus and Poisson's ratio—a total of 9 constants to describe the relationship
between forces/moments and strains/curvatures.

Techniques that take advantage of the anisotropic properties of the materials include mortise and tenon joints (in
natural composites such as wood) and Pi Joints in synthetic composites.

Failure
Shock, impact, or repeated cyclic stresses can cause the laminate to separate at the interface between two layers, a
condition known as delamination. Individual fibres can separate from the matrix e.g. fibre pull-out.

Composites can fail on the microscopic or macroscopic scale. Compression failures can occur at both the macro scale
or at each individual reinforcing fibre in compression buckling. Tension failures can be net section failures of the part
or degradation of the composite at a microscopic scale where one or more of the layers in the composite fail in tension
of the matrix or failure of the bond between the matrix and fibres.

Some composites are brittle and have little reserve strength beyond the initial onset of failure while others may have
large deformations and have reserve energy absorbing capacity past the onset of damage. The variations in fibres and
matrices that are available and the mixtures that can be made with blends leave a very broad range of properties that
can be designed into a composite structure. The best known failure of a brittle ceramic matrix composite occurred
when the carbon-carbon composite tile on the leading edge of the wing of the Space Shuttle Columbia fractured when
impacted during take-off. It led to catastrophic break-up of the vehicle when it re-entered the Earth's atmosphere on 1
February 2003.

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Compared to metals, composites have relatively poor bearing strength.

Testing
To aid in predicting and preventing failures, composites are tested before and after construction. Pre-construction
testing may use finite element analysis (FEA) for ply-by-ply analysis of curved surfaces and predicting wrinkling,
crimping and dimpling of composites.[17][18] [19]Materials may be tested during manufacturing and after construction
through several nondestructive methods including ultrasonics, thermography, shearography and X-ray
radiography,[20] and laser bond inspection for NDT of relative bond strength integrity in a localized area.

See also
Aluminium composite panel
American Composites Manufacturers Association
Chemical vapour infiltration
Composite (disambiguation)
Composite laminates
Epoxy granite
Hybrid material
Nanocomposites
Rule of mixtures
Scaled Composites, American aerospace company founded by Burt Rutan
Void (composites)

References
1. M. A. McEvoy and N. Correll. Materials that couple sensing, actuation, computation, and communication. Science
347(6228), 2015. (http://www.sciencemag.org/content/347/6228/1261689.abstract)
2. Autonomous Materials will let future robots change color and shift shape, Popular Science, March 19, 2015. (htt
p://www.popsci.com/future-robotic-will-have-autonomous-materials)
3. Shaffer, G.D. "An Archaeomagnetic Study of a Wattle and Daub Building Collapse." Journal of Field Archaeology,
20, No. 1. Spring, 1993. 59-75. JSTOR. Accessed 28 January 2007 (http://jstor.org/search)
4. "Minerals commodity summary – cement – 2007" (http://minerals.usgs.gov/minerals/pubs/commodity/cement/inde
x.html). US United States Geological Survey. 1 June 2007. Retrieved 16 January 2008.
5. "History of Composite Materials" (http://www.mar-bal.com/language/en/applications/history-of-composites/). Mar-
Bal Incorporated. Retrieved 2018-01-03.
6. "History of Composite Materials" (http://www.mar-bal.com/language/en/applications/history-of-composites/). Mar-
Bal Incorporated. Retrieved 2018-01-03.
7. Heather Lechtman and Linn Hobbs "Roman Concrete and the Roman Architectural Revolution", Ceramics and
Civilization Volume 3: High Technology Ceramics: Past, Present, Future, edited by W.D. Kingery and published by
the American Ceramics Society, 1986; and Vitruvius, Book II:v,1; Book V:xii2
8. "Slabs On Grade" (http://www.constructionknowledge.net/concrete/concrete_basics.php). Construction
Knowldegs.net. Retrieved January 3, 2018.
9. "Behaviour of Concrete Under Tension" (https://theconstructor.org/practical-guide/concrete-under-tension/6805/).
The Constructor. Retrieved January 3, 2018.
10. AW ZIA, AR SHAH, SH LEE and JI SONG. Development of diamond-like-carbon coated abaca-reinforced
polyester composites for hydrophobic and outdoor structural applications. Polymer Bulletin 72(11), 2015, 2797–
2808. (https://link.springer.com/article/10.1007/s00289-015-1436-y)
11. http://www.ncsu.edu/bioresources/BioRes_02/BioRes_02_4_534_535_Hubbe_L_BioResJ_Editorial_LoveHate.pdf
12. David Hon and Nobuo Shiraishi, eds. (2001) Wood and cellulose chemistry, 2nd ed. (New York: Marcel Dekker),
p. 5 ff.

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13. Khurram, Shehzad; Xu, Yang; Chao, Gao; Xianfeng, Duan (2016). "Three-dimensional macro-structures of two-
dimensional nanomaterials". Chemical Society Reviews. 45 (20): 5541. doi:10.1039/C6CS00218H (https://doi.org/
10.1039%2FC6CS00218H). PMID 27459895 (https://www.ncbi.nlm.nih.gov/pubmed/27459895).
14. "Vacuum Bags For Woodworking" (http://www.prowoodworkingtips.com/Vacuum_Systems_pg_4_-_Vacuum_bag
s.html).
15. Kim, Hyoung Seop (2000-09-30). "On the rule of mixtures for the hardness of particle reinforced composites" (htt
p://www.sciencedirect.com/science/article/pii/S0921509300009096). Materials Science and Engineering: A. 289
(1): 30–33. doi:10.1016/S0921-5093(00)00909-6 (https://doi.org/10.1016%2FS0921-5093%2800%2900909-6).
16. Courtney, Thomas H. (2000). Mechanical Behavior of Materials (2nd ed.). Long Grove, IL: Waveland Press, Inc.
pp. 263–265. ISBN 978-1-57766-425-3.
17. Waterman, Pamela J. "The Life of Composite Materials" (http://66.195.41.10/Articles/Feature/The-Life-of-Composi
te-Materials-200704101800.html). Desktop Engineering Magazine. April 2007.
18. Aghdam, M. M.; Morsali, S. R. (2013-11-01). "Damage initiation and collapse behavior of unidirectional metal
matrix composites at elevated temperatures" (http://www.sciencedirect.com/science/article/pii/S09270256130034
67). Computational Materials Science. 79: 402–407. doi:10.1016/j.commatsci.2013.06.024 (https://doi.org/10.101
6%2Fj.commatsci.2013.06.024).
19. Kishore., Debnath,. Primary and Secondary Manufacturing of Polymer Matrix Composites (https://www.worldcat.o
rg/oclc/1004424029). Singh, Inderdeep. [Place of publication not identified]. ISBN 9781498799300.
OCLC 1004424029 (https://www.worldcat.org/oclc/1004424029).
20. Matzkanin, George A.; Yolken, H. Thomas. "Techniques for the Nondestructive Evaluation of Polymer Matrix
Composites" (http://ammtiac.alionscience.com/pdf/AQV2N4.pdf) (PDF). AMMTIAC Quarterly. 2 (4).

Further reading
Robert M. Jones (1999). Mechanics of Composite Materials (2nd ed.). Taylor & Francis. ISBN 9781560327127.
Autar K. Kaw (2005). Mechanics of Composite Materials (2nd ed.). CRC. ISBN 0-8493-1343-0.
Handbook of Polymer Composites for Engineers By Leonard Hollaway Published 1994 Woodhead Publishing
Madbouly, Samy, Chaoqun Zhang, and Michael R. Kessler. Bio-Based Plant Oil Polymers and Composites.
William Andrew, 2015.
Matthews, F.L.; Rawlings, R.D. (1999). Composite Materials: Engineering and Science. Boca Raton: CRC Press.
ISBN 0-8493-0621-3.

External links
CompositesPress | The Composites Social Network (https://www.compositespress.com)
Composites Design and Manufacturing HUB (http://www.cdmhub.org/)
Distance learning course in polymers and composites (https://web.archive.org/web/20070219024138/http://www3.
open.ac.uk/courses/bin/p12.dll?C01T838)
High Density Composites Replace Lead (http://www.ecomass.com/media/High-Density-Composites-Replace-Lea
d.pdf)
Strength of Composites (http://www.kokch.kts.ru/me/t9/SIA_9_Composites.pdf)
Composite Sandwich Structure of Minardi F1 Car (https://web.archive.org/web/20080528131849/http://www.nena
stran.com/newnoran/chPDF/CASE_Chassis_Design.pdf)
OptiDAT composite material database (http://www.wmc.eu/optimatblades_optidat.php)
Tests originally developed to test metals have been adapted by the industry to test composites (http://www.wmtr.c
om/en.composites.html)
World leading centre for advanced composites (http://www.bristol.ac.uk/composites/)

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