Composite Materials

Ahmed W. Moustafa
Lecture (1)

COMPOSITE
MATERIALS

Technology and Classification of

Composite Materials
Metal Matrix Composites
Ceramic Matrix Composites
Polymer Matrix Composites
Guide to Processing Composite
Materials

Classification Scheme
for
Composite
Materials
Metal Matrix Composites
(MMCs) mixtures of
1.

2.

ceramics and metals, such as cemented

carbides and other cermets
Ceramic Matrix Composites (CMCs) Al2O3 and
SiC imbedded with fibers to improve
properties, especially in high temperature
applications

3.

The least common composite matrix

Polymer Matrix Composites (PMCs)

thermosetting resins are widely used in PMCs

Examples: epoxy and polyester with fiber

reinforcement, and phenolic with powders

The Reinforcing Phase

(Secondary Phase)

Function is to reinforce the primary phase

Imbedded phase is most commonly one of
the following shapes:
Fibers
Particles
Flakes

In addition, the secondary phase can take

the form of an infiltrated phase in a skeletal
or porous matrix
Example: a powder metallurgy part infiltrated
with polymer

Figure 9.1 Possible physical shapes of imbedded phases in

composite materials: (a) fiber, (b) particle, and (c) flake

Fibers
Filaments of reinforcing material, usually
circular in crosssection
Diameters range from less than 0.0025 mm
to about 0.13 mm, depending on material
Filaments provide greatest opportunity for
strength enhancement of composites
The filament form of most materials is
significantly stronger than the bulk form
As diameter is reduced, the material becomes
oriented in the fiber axis direction and probability
of defects in the structure decreases significantly

Continuous vs.
Discontinuous Fibers

Continuous fibers - very long; in theory,

they offer a continuous path by which a
load can be carried by the composite part
Discontinuous fibers (chopped sections of
continuous fibers) - short lengths (L/D =
roughly 100)
Important type of discontinuous fiber are
whiskers hair-like single crystals with
diameters down to about 0.001 mm (0.00004
in.) with very high strength

Fiber Orientation
Three Cases

Onedimensional reinforcement, in
which maximum strength and stiffness
are obtained in the direction of the fiber
Planar reinforcement, in some cases in
the form of a twodimensional woven
fabric
Random or threedimensional in which
the composite material tends to
possess isotropic properties

Figure 9.3 Fiber orientation in composite materials:

(a) onedimensional, continuous fibers; (b) planar, continuous
fibers in the form of a woven fabric; and (c) random,
discontinuous fibers

Materials for Fibers

Fiber materials in fiberreinforced

composites:

Glass most widely used filament

Carbon high elastic modulus
Boron very high elastic modulus
Polymers - Kevlar
Ceramics SiC and Al2O3
Metals - steel

The most important commercial use of

fibers is in polymer composites

Particles and Flakes

A second common shape of imbedded phase is

particulate, ranging in size from microscopic to
macroscopic
Flakes are basically twodimensional particles
small flat platelets
The distribution of particles in the composite
matrix is random, and therefore strength and
other properties of the composite material are
usually isotropic
Strengthening mechanism depends on particle
size

The Interface

There is always an interface between constituent

phases in a composite material
For the composite to operate effectively, the
phases must bond where they join at the interface

Figure 9.4 Interfaces between phases in a composite material:

(a) direct bonding between primary and secondary phases

Interphase

In some cases, a third ingredient must be added to

achieve bonding of primary and secondary phases
Called an interphase, this third ingredient can be
thought of as an adhesive

Figure 9.4 Interfaces between phases: (b) addition of a third

ingredient to bond the primary phases and form an interphase

Another Interphase
Interphase consisting of a solution of primary and
secondary phases

Figure 9.4 Interfaces and interphases between phases in a

composite material: (c) formation of an interphase by solution
of the primary and secondary phases at their boundary

Properties of
Composite Materials

In selecting a composite material, an

optimum combination of properties is
usually sought, rather than one particular
property
Example: fuselage and wings of an aircraft must
be lightweight and be strong, stiff, and tough

Several fiberreinforced polymers possess this

combination of properties

Example: natural rubber alone is relatively weak

Adding significant amounts of carbon black to NR

increases its strength dramatically

Properties are
Determined by Three
Factors:
1.

2.

3.

The materials used as component

phases in the composite
The geometric shapes of the
constituents and resulting structure
of the composite system
The manner in which the phases
interact with one another

Figure 9.5 (a) Model of a fiberreinforced composite material

showing direction in which elastic modulus is being estimated
by the rule of mixtures (b) Stressstrain relationships for the
composite material and its constituents. The fiber is stiff but
brittle, while the matrix (commonly a polymer) is soft but
ductile.

Figure 9.6 Variation in elastic modulus and tensile strength as

a function of direction of measurement relative to longitudinal
axis of carbon fiberreinforced epoxy composite

Fibers Illustrate
Importance of Geometric
Shape
Most materials have tensile strengths several

times greater as fibers than in bulk

By imbedding the fibers in a polymer matrix,
a composite material is obtained that avoids
the problems of fibers but utilizes their
strengths

The matrix provides the bulk shape to protect the

fiber surfaces and resist buckling
When a load is applied, the lowstrength matrix
deforms and distributes the stress to the
highstrength fibers

Other Composite
Structures

Laminar composite structure

conventional
Sandwich structure
Honeycomb sandwich structure

Laminar Composite Structure

Two or more layers bonded together in an integral piece
Example: plywood in which layers are the same
wood, but grains are oriented differently to increase
overall strength of the laminated piece

Figure 9.7 Laminar composite

structures: (a) conventional laminar
structure

Sandwich Structure Foam Core

Consists of a relatively thick core of low density
foam bonded on both faces to thin sheets of a
different material

Figure 9.7 Laminar

composite structures: (b)
sandwich structure using foam
core

Sandwich Structure Honeycomb Core

An alternative to foam core

Either foam or honeycomb achieves high
strengthtoweight and stiffnesstoweight ratios

Figure 9.7 Laminar

composite structures: (c)
sandwich structure using
honeycomb core

Other Laminar
Composite Structures

Automotive tires - consists of multiple layers

bonded together
FRPs - multilayered fiberreinforced plastic panels
for aircraft, automobile body panels, boat hulls
Printed circuit boards - layers of reinforced plastic
and copper for electrical conductivity and insulation
Snow skis - composite structures consisting of
layers of metals, particle board, and phenolic
plastic
Windshield glass - two layers of glass on either side
of a sheet of tough plastic

Metal Matrix
Composites (MMCs)
A metal matrix reinforced by a second
phase
Reinforcing phases:
1. Particles of ceramic (these MMCs are
commonly called cermets)
2. Fibers of various materials: other metals,
ceramics, carbon, and boron

Cermets
MMC with ceramic contained in a metallic
matrix
The ceramic often dominates the mixture,
sometimes up to 96% by volume
Bonding can be enhanced by slight
solubility between phases at elevated
temperatures used in processing
Cermets can be subdivided into
1. Cemented carbides most common
2. Oxidebased cermets less common

Cemented Carbides
One or more carbide compounds bonded in a
metallic matrix
The term cermet is not used for all of these
materials, even though it is technically correct
Common cemented carbides are based on
tungsten carbide (WC), titanium carbide (TiC),
and chromium carbide (Cr3C2)
Tantalum carbide (TaC) and others are less
common
Metallic binders: usually cobalt (Co) or nickel
(Ni)

Figure 9.8 Photomicrograph (about 1500X) of cemented

carbide with 85% WC and 15% Co (photo courtesy of
Kennametal Inc.)

Figure 9.9 Typical plot of hardness and transverse

rupture strength as a function of cobalt content

Applications of
Cemented Carbides

Tungsten carbide cermets (Co binder) - cutting

tools are most common; other: wire drawing dies,
rock drilling bits and other mining tools, dies for
powder metallurgy, indenters for hardness testers
Titanium carbide cermets (Ni binder) - high
temperature applications such as gasturbine
nozzle vanes, valve seats, thermocouple
protection tubes, torch tips, cutting tools for
steels
Chromium carbides cermets (Ni binder) - gage
blocks, valve liners, spray nozzles, bearing seal
rings

Ceramic Matrix
Composites (CMCs)
A ceramic primary phase imbedded with a
secondary phase, which usually consists of fibers
Attractive properties of ceramics: high stiffness,
hardness, hot hardness, and compressive
strength; and relatively low density
Weaknesses of ceramics: low toughness and bulk
tensile strength, susceptibility to thermal cracking
CMCs represent an attempt to retain the desirable
properties of ceramics while compensating for
their weaknesses

Polymer Matrix
Composites (PMCs)
A polymer primary phase in which a secondary
phase is imbedded as fibers, particles, or
flakes
Commercially, PMCs are more important than
MMCs or CMCs
Examples: most plastic molding compounds,
rubber reinforced with carbon black, and
fiberreinforced polymers (FRPs)
FRPs are most closely identified with the term
composite

FiberReinforced
Polymers (FRPs)
A PMC consisting of a polymer matrix
imbedded with highstrength fibers
Polymer matrix materials:
Usually a thermosetting (TS) plastic such as
unsaturated polyester or epoxy
Can also be thermoplastic (TP), such as
nylons (polyamides), polycarbonate,
polystyrene, and polyvinylchloride
Fiber reinforcement is widely used in rubber
products such as tires and conveyor belts

Fibers in PMCs

Various forms: discontinuous (chopped),

continuous, or woven as a fabric
Principal fiber materials in FRPs are glass,
carbon, and Kevlar 49
Less common fibers include boron, SiC, and
Al2O3, and steel
Glass (in particular Eglass) is the most
common fiber material in today's FRPs; its
use to reinforce plastics dates from around
1920

Common FRP Structure

Most widely used form of FRP is a laminar

structure, made by stacking and bonding thin
layers of fiber and polymer until desired
thickness is obtained
By varying fiber orientation among layers, a
specified level of anisotropy in properties can
be achieved in the laminate
Applications: parts of thin crosssection, such
as aircraft wing and fuselage sections,
automobile and truck body panels, and boat
hulls

FRP Properties

High strengthtoweight and modulustoweight

ratios
Low specific gravity - a typical FRP weighs only
about 1/5 as much as steel; yet, strength and
modulus are comparable in fiber direction
Good fatigue strength
Good corrosion resistance, although polymers
are soluble in various chemicals
Low thermal expansion - for many FRPs, leading
to good dimensional stability
Significant anisotropy in properties

FRP Applications

Aerospace much of the structural weight of

todays airplanes and helicopters consist of
advanced FRPs
Automotive somebody panels for cars and
truck cabs
Continued use of low-carbon sheet steel in cars is
evidence of its low cost and ease of processing

Sports and recreation

Fiberglass reinforced plastic has been used for boat
hulls since the 1940s
Fishing rods, tennis rackets, golf club shafts,
helmets, skis, bows and arrows.

Figure 9.11 Composite materials in the Boeing 757

(courtesy of Boeing Commercial Airplane Group)

Other Polymer Matrix

Composites

In addition to FRPs, other PMCs contain

particles, flakes, and short fibers as the
secondary phase
Called fillers when used in molding
compounds
Two categories:
1. Reinforcing fillers used to strengthen or
otherwise improve mechanical properties

Examples: wood flour in phenolic and amino resins; and

carbon black in rubber

2. Extenders used to increase bulk and reduce

cost per unit weight, but little or no effect on
mechanical properties

Guide to Processing
Composite Materials

The two phases are typically produced

separately before being combined into the
composite part
Processing techniques to fabricate MMC and
CMC components are similar to those used
for powdered metals and ceramics
Molding processes are commonly used for
PMCs with particles and chopped fibers
Specialized processes have been developed
for FRPs