INTRODUCTION

Composite materials are considered the most advanced and adaptable engineering materials known to man. A composite material is the combination of 2 or more distinct materials into one engineering material where the phases are still significant The word composite is derived from the latin word componere which means to put together . The components are put together in order to suppress their undesirable properties in favor of their desirable properties. This does not include metal alloys or polymer blends which combines at an atomic level.

Evolution of Material

During the stone age, flint was used as cutting material. Metals were then least important. At that time, natural polymers (wood, skins, fibers) dominated in the engineering applications. (house, weapons, boats)

 Later, metal working evolved and development dominates engineering achievement until into 20th century. In 1960s the use of metal in engineering material declined. Polymers, composites and ceramics regaining the relative importance to man. However these are synthetic materials. Examples of natural composites are trees, wood, bone or mollusk shell. Natural composites tend to be weaker and less stiff than synthetic composites, but are often superior in terms of design and manufacture. E.g: Spider Web Natural composites are also smart materials in that they adapt to the environment.

Synthetic composites- first composites are believed to be made by the Egyptians who used straw to reinforce clay to make brick. They use papyrus reeds (placed parallel to each other forming layers, and then stacked perpendicular to each other in alternate directions, dried under pressure to form paper like sheets.

The Composite Concept

- Composites in most cases comprises of a bulk phase enclosing a fibrous reinforcing phase; called matrix and reinforcement.
Matrix Gives shape to the composites Bind the reinforcement together Introduce external loads to the reinforcement Protect it from environmental effects(high temperature, water, UV light, etc) Fiber Reinforcement Carries, the structural loads Dictates microscopic stiffness & strength
Matrix

Fiber reinforcement

BASIC KNOWLEDGE
Most impressive mechanical properties are found in composites with continuous and aligned reinforcement. Why polymer composites are used in most structural applications? -they offer a given property -often excellent stiffness and strength at a lower weight than the competition (steel, concrete, wood). Properties of composite materials:

Properties of Polymer Composites

Advantages - corrosion resistance - electrical insulation - reduction in tool and assembly cost - decrease in maintenance cost - exceptional formability Disadvantages - high raw material cost - difficult manufacturing - lack of knowledge/experience

Composites are therefore certainly not appropriate in all applications; a critical assessment of the material alternatives must always be made in term of performance- cost ratio.

Transport Applications
Is a dominant sector of composites and the fastest growing. High specific stiffness and strength but lighter parts can be exploited to reduce fuel consumption or to increase payload. (commercial vehicles) Better feasible mold design geometrically can be achieved by using composites

In some truck and bus applications, usually body panels and dashboards are designed from composites. Composites also turn up in an increasing number of nonstructural or semi- structural under the hood applications, where temperatures are of the order of 150oC or higher. More applications such as noise shields, heat shields, air intake manifold, engine top cover etc.

 In F1 and motorcycle racing, they use composites: -save weight and thus gain performance. Carbon fiber and Kevlar are being used as they are lightweight, high in strength with good heat resistance. Body parts of sports cars are designed as composite body panel fastened to a conventional steel space frame like dodge viper, skyline and the new Mercedes CLK.

Boat Building By the 1950's, boat builders began the transition to fiberglass hulls. Such designs are:

-easier to build -significantly lower in cost -complex shapes were easily formed in fiberglass when compared to wood or metal. Buyers got attractive new styles that were lower cost, easier to transport, extremely durable and easy to maintain, since fiberglass does not rust like steel nor rot like wood.

In the Defense world, marine composites offer similar advantages. Steel ships rust, requiring constant maintenance. The heavy weight of steel ships also places limits on their speed and increases fuel consumption: heavy ships take a lot of fuel to move. Because warships often have to worry about explosive mines, the magnetic signature of ships is a concern to all sailors. Composites are non-magnetic and make an ideal material for any ship expected to face mine warfare conditions. (MCMV)

 Aerospace and Military Applications

The main reason to use composites: -high profile material is needed -the ultimate in performance -saved weight is seen as increase in load carrying capability or a matter of life and death. The less insignificant fact is that composites can lower manufacturing cost, better fatigue resistance than light metal. Recently, glass reinforced composites have been used in aircraft radomes (nose cones) and stealth properties (although most of the stealth technique depends on the angular geometry to reflect minimum of radiation).

 In commercial and civilian aircraft applications, potential weight saving is highly valued. Here, the use of carbon reinforced epoxy sandwich with honeycomb core as a replacement of metal rudder, clearly resulted in a reduction of 22 percent weight and number of parts from 17000 to 4800 (since bonding eliminates rivets)

In aerospace, weight reduction by using composites can be seen clearly from the launch of The Pegasus XL, where an almost composite complete structure can be seen. Composites are well suited to applications where primary load case is (internal) pressure. For launching, many components are exposed to such high temperatures where composites containing ceramic and carbon matrices are used.

Construction Applications Composites in construction come under industrial and agricultural equipment and corrosion resistant equipment. The most significant example of application is the bridge building. The Aberfeldy footbridge in Scotland utilizes small amount of heavy machinery and concrete.

- In other industries such as chemical plants, waste water treatment plants, composites are used in construction applications such as handrails, water tanks and silos to eliminate corrosion issues and reduce maintenance costs in replacing steel components.

Electrical and Sanitary Applications

In electrical applications, dielectric strength of the glass-reinforced composites is more important than the structural capabilities. This includes circuit boards, equipment housings, transformer spacers and cable trays. Ladder rail is a common example where direct electrical contact between electrician and potentially hot wires and ground is obvious.

- In sanitary applications such as shower enclosures, bath tubs, spas, sinks and cabinets composites are used as they possess design freedom and economically proven on the production and maintenance considerations.

Sports Applications
In some applications where performance and weight is the deciding factor, it is vital to use composites to enhance the properties In ski, tennis, golf and squash applications, the use of Kevlar, graphite or carbon reinforcement is vital as they actually change the traditional approach of the game as well.

Other Applications
The first one is medicine, where composites for quite some time have been used in patient support tables in X-ray machines. These tables offer great stiffness while still being transparent to the radiation in order not to obscure the radiograph. Composites are also being investigated for artificial joints to replace the more conventional metal components used in, for example, artificial hip joints. A problem with inserting a titanium hip implant into the femur is that the stiffness of the implant is so much greater than that of the bone, which gradually leads to bone deterioration. With composites the stiffness can be tailored to that of the bone to eliminate this problem.

Other Usage
A somewhat unusual composite application is in musical instrument where string instruments so far have received the most attention. With careful design and manufacture an acoustic guitar, or for that matter any string instrument, can be made to satisfy the pickiest musician. Advantages: -possibility of tailoring the instrument to whatever the customer wants -the instrument is not sensitive to climate changes or transportation damage -no rare woods on the brink extinction are used.