Unit- 3 Composites Materials

Composites materials are produced by combining two dissimilar materials into a new material tht
,may be better suited for a particular application than either of the Original material alone.
Eg. Glass re-in forced plastic.
Plastic is alone weak and has Low elastic Modulus, however it is stable chemically and
constitutes an excellent matrix for the composites.
The glass fibre provides the strength and stiffness, their modulus of elasticity is 50 times
greater than that of Plastic.
However GRP has much chemical resistant and have high modulus of elasiticity.
Modern technologies require materials with unusual combination of properties that cannot be met
by the conventional metal and alloys, ceramics and polymer materials.
Materials can be combined in composites to produce a unique characteristics such as stiffness,
toughness, and high temperature strength, that can be used for aerospace, underwater and
transportation applications.
Many composites materials are composed of just two phases,

One is termed as matrix, which is continuous and

Another surrounds the other phase, often called the dispersed phase.

Classification of Composite materials

One Simple Scheme for the Classification of the Composite materials is as follows,
Composites
1. Particle re-in forced
a. large particle
b. Dispersion strengthened
2. Fiber re-in forced
a. Continuous (aligned)
b. Discontinous (short)
3. Structural
a. Laminates
b. Sanwich panels

Particle reinforced Composites

The Dispersed phase for particle re-in forced composites is Equi-axised. Ie., particle dimensions
are approx the same in all Direction.
Types (based on re-in forcement and strengthening mechanism)
1. Large particle
2. Dispersion Strengthened
Large Particle Composites
The term large is used to indicate that particle matrix interactions cannot be treated on the atomic
or molecular level; rather continuum mechanism is used.
For most of the Composites the particulate phase is harder and stiffer than the matrix.
The re-in forcing particles tend to restrain movement of the matrix phase in the vicinity of
each particle.
Matrix transfers some of the applied stress to the particle, which bears a fraction of Load.

The degree of reinforcement or improvement of the mechanical behavior depends on

strong bonding at the matrix particle re-in force.
A filler improves the Properties of the materials and/or replace some of the polymer volume with a
less expensive materials.
Eg. Concrete - Cement (matrix), Sand and gravel (the particulates)
o The particles should be approx the same dimension in all directions (equiaxed).
o For effective re-in forcement the particles should be small and evenly distributed throughout
the matrix.
o The mechanical properties are enhanced with increasing particulate content.
Large Particulates Composites are utilized with all three material types
Metal
Polymer
Ceramics
Eg. Cermets (Ceramic and metals) most common cermets are Cemented Carbide, which has
extremely hard particles of a refractory carbide ceramics such as Ti C or W C, embedded in
matrix of metal such as Cobalt and Nickel.
These are used for extensively as cutting tools for hardened steels.
Both elastomers and plastics are frequently re-inforced with various particulate materials.
Use of Rubbers with Carbon Black, when added to Vulcanize rubber this extremely inexpensive
materials enhances tensile strength, toughness and tear and abrasive resistance. Automobile
tyres contain on the Order of 15 30 % vol of Carbon Black.

Dispersion Strengthened Composites

Metals and metal alloys may be strengthened and hardened by the uniform dispersion of
several volume per cent of fine particles of very hard and inert materials.
Dispersion may be
o Metallic - inert metals
o metallic Oxides or Oxides material - inert Material
Strengthening mechanism involves interaction between the particles and Dislocation
within the Matrix, as with precipitation hardening.
The Dispersion strengthening effect is not as pronounced as with precipitation
hardening however the strengthening is retained at elevated temperatures and for
extended time periods because particles are chosen to be unreactive with the matrix
phase.
Eg. 1 The High temperature strength if Ni alloy may be enhanced significantly by addition of about
3 % vol of thoria (ThO2) as finely dispersed particles, this is known as thoria dispersed Nickel or
TD Ni.
Eg. 2 A very thin and adherent Alumina Coating is caused to form on the surface of extremely
small flakes of Al, which are dispersed within al Al metal matrix, this material is termed as Sintered
Al powder S Al P.

Fiber Re-inforced Composites

Fiber re-inforced composites are
o High strength and/or stiffness on a Weight basis.
o High Specific Strength
o High moduli that Utilizes low-density fiber and matrix materials.
The arrangement or Orientation of the fibers relative to one another, the fiber concentration and
distribution all have a Significant influence on the strength and other properties of fiber re-inforced
composites.
Some Critical length is necessary for the effective strengthening and stiffness of the composite
material. The Critical length (lc ) is dependent on
o the fiber diameter (d)
o
o

its ultimate or tensile strength (f) and

the fiber matrix bond strength or shear yield strength of the material (

lc =
For number of glass and carbon fiber matrix Combination, this lc = 1 mm, which d = 20 150 times fiber
diameter.

l >> lc
l lc

Fiber for which

( l > 15 lc ) are termed as Continuous

are termed as Discontinuous or Short fibers.

1. Continuous Fiber
For Continuous fiber re-inforcement the strain in the matrix and the strain in the fiber under load
are initially the same. At Low stress both deform elastically but increasing load, the matrix may
deform plastically while the fiber still will be elastic.
to the fiber direction occur at the very low stresses. This appear to be the
effect of stress concentration at the fiber reinforcement. To counter act this cross-plied
laminates
.
2. Discontinuous Fiber
S

p c

fiber is broken at the fiber end which are carrying stress than the middle part of the fiber.
The strength of the Discontinuous fiber is always lower than the Continuous fibre structure.
Eg. Chopped Glass fiber
3. Random, Short and Discontinuous Fiber
Application involves multi directional applied stresses, uses such fiber which are randomly
oriented in the matrix material.

Matrix Phase
Functions
1. The matrix phase binds the fiber together and acts as the medium by which an
externally applied stress is transmitted and distributed to the fibers; only a small
proportion of the applied load is sustained by the matrix phase.
The Matrix material should be
Ductile
Elastic modulus of the fiber should be much higher than that of the matrix.
2. The matrix protects the individual fibers from the surface damage as a result of
mechanical abrasion or chemical reactions with the environment.
3. The matrix separates the Fiber by virtue
Relative softness
Plasticity
Prevents the propagation of brittle cracks from fiber to fiber
4. It is essential that adhesive bonding forces between the fiber and matrix be high.
5. Metals such as Al, Cu and Commercial thermoplastic and thermosetting polymers are used
as matrix materials.

Fibre Phase
1. Fibers can be any Polymer, metal or ceramics that can be drawn into a thin long filament.
2. Important characteristics is that small diameter fiber is much stronger than the bulk
material, because of the probability of a critical surface flaw that can lead to fracture
diminishes, with decrease specimen volume and this is made as advantage.

3. On basis of Diameter and Character, fibers are grouped into three different classification
(1) Whiskers
(2) fibers
(3) Wires
(1) Whiskers
Very thin Single crystal that have extremely large length to diameter ratio.
High degree of crystalline perfection hence flaw free
High strength
They are highly expensive and it is difficult to incorporate in matrix.
Eg. Graphite, Si C, Si N, Al2O3
(2) Fibers
They are either polycrystalline or amorphous and have small diameter.
They are either polymers or ceramics
Eg. Aramids, glass, Carbon, Boron, Si C, Si N, Al 2O3
(3) Fine Wires
Relatively Large Diameter
Eg. Steel, Mo, W.
Wires are utilized as Steel re-inforcement in Automobile tryes, in filament Wound rocket casing
and in wire wound high pressure hoses.

Structural Composites
Structural Composites composed of both homogeneous and Composite materials the property of
which depends not only on the properties of the constituents but also on the geometrical design of
the various structural elements.
Types
1. Laminar composites
2. Sandwich Panels.
Laminar Composites
1. Two dimensional Sheets that have a preferred high strength direction such as Wood and
aligned Plastic re-inforced plastics.
2. The layers are stacked and Subsequently cemented together such that the orientation of
the high-strength direction varies with each successive layer.
3. Lamination may be constructed fabric material such as cotton, plastic, paper or woven
fiber embedded in a plastic.

Sandwich Panels
1. Two strong outer Sheets or faces sperated by a layer of less dense material or core, which
are lower stiffness and low strength.
2. Faces bear most of the in-plane load and also transverse bending stresses.
3. Function :
a. It separates the faces and resists deformation perpendicular to the face Plane
b. Provides a certain degree of shear rigidity along planes which are perpendicular to the
faces.
Eg.

Al Alloys, Fiber reinforced plastics, Ti, Steel and plywood.

METAL MATRIX COMPOSITES

A metal matrix composite (MMC) is composite material with at least two constituent parts,
one being a metal. The other material may be a different metal or another material, such
as aceramic or organic compound. When at least three materials are present, it is called
a hybrid composite. An MMC is complementary to a cermet
MMCs are made by dispersing a reinforcing material into a metal matrix. The reinforcement
surface can be coated to prevent a chemical reaction with the matrix. For example, carbon
fibers are commonly used in aluminum matrix to synthesize composites showing low density
and high strength. However, carbon reacts with aluminum to generate a brittle and water-soluble
compoundAl 4C3 on the surface of the fiber. To prevent this reaction, the carbon fibers are
coated with nickel or titanium boride.
Matrix
The matrix is the monolithic material into which the reinforcement is embedded, and is
completely continuous. This means that there is a path through the matrix to any point in the
material, unlike two materials sandwiched together. In structural applications, the matrix is usually
a lighter metal such as aluminum, magnesium, or titanium, and provides a compliant support
for the reinforcement. In high temperature applications, cobalt and cobalt-nickel alloy matrices
are common.
Reinforcement
The reinforcement material is embedded into the matrix. The reinforcement does not always serve
a purely structural task (reinforcing the compound), but is also used to change physical properties
such as wear resistance, friction coefficient, or thermal conductivity. The reinforcement can be
either continuous, or discontinuous. Discontinuous MMCs can be isotropic, and can be worked
with standard metalworking techniques, such as extrusion, forging or rolling. In addition, they may
be machined using conventional techniques, but commonly would need the use of polycrystaline
diamond tooling (PCD).
Continuous reinforcement uses monofilament wires or fibers such as carbon fiber or silicon
carbide. Because the fibers are embedded into the matrix in a certain direction, the result is
ananisotropic structure in which the alignment of the material affects its strength. One of the first
MMCs used boron filament as reinforcement. Discontinuous reinforcement uses "whiskers", short
fibers, or particles. The most common reinforcing materials in this category are alumina and
[1]
silicon carbide.
MMC manufacturing can be broken into three types: solid, liquid, and vapor.
Solid state methods
Powder blending and consolidation (powder metallurgy): Powdered metal and discontinuous
reinforcement are mixed and then bonded through a process of compaction, degassing, and
thermo-mechanical treatment (possibly via hot isostatic pressing (HIP) or extrusion).
Foil diffusion bonding: Layers of metal foil are sandwiched with long fibers, and then pressed
through to form a matrix.

Liquid state methods

Electroplating / Electroforming: A solution containing metal ions loaded with reinforcing
particles is co-deposited forming a composite material.
Squeeze casting: Molten metal is injected into a form with fibers preplaced inside it.
Spray deposition: Molten metal is sprayed onto a continuous fiber substrate.
Reactive processing: A chemical reaction occurs, with one of the reactants forming the matrix
and the other the reinforcement.
Vapor deposition
Physical vapor deposition: The fiber is passed through a thick cloud of vaporized metal,
coating it.

CONCRETE
Concrete is a building and structural material obtained by mixing
1. Cement,
2. Mineral aggregates (sand and gravels)
3. Water
In suitable proportion so that the result is a Plastic and workable mass that can be molded into
any shape.
The Quality of Concrete depends on
the properties of the materials used,
the methods of batching and mixing
the methods of Construction
Mixes with Cement-sand-gravel or crushed stone volume proportions to
1
:
1.5
:
3
1
:
2
:
4
1
:
3
:
5
Except for cement rich mixtures now-a-days the following proportion are used
1
:
2
:
3.5
1
:
2.5
:
4
1
:
3
:
5
Water addition is for the required workability for any application.

ASPHALT CONCRETE
Asphalt concrete is competitive with cements concrete for use in construction of
highways, roadways and other surfaces.
It is made up of by mixing a suitable graded hot aggregate produced from crushed rock
with asphalt cements
ASPHALT = asphaltic bitumen and bitumen is generally synonymous.
Asphalt is a
black to dark brown solid or semisolid material consisting predominantly of mixtures of
hydrocarbon that are completely soluble disulfide.
Thermoplastic material and it softens on heating and hardens on cooling.
Resistance to non-oxidizing acids and corrosive salts but it is attacked by H 2SO4 and many
Organic Solvents.
soild or semisolid products and require heating to convert them into a fluid state before
application.
Asphalt are processed to
Asphalt cements
Liquid asphalt products known as Cutbacks
Asphalt emulsion
Process : Asphalt cements is used as the hot milk of asphalt cements with suitable grade
minerals aggregates spread and compacted on rolling a temperature between 140 and 80 C.

It cures immediately on cooling. Depending on the size of the graded aggregates asphalt concrete
can contain 5 8 % of pure asphalt cements

Asphalt vs. Concrete Driveway

Asphalt Driveway

Concrete Driveway

Cost

$2.50 - $4.00 /sq.ft.

$4.00 - $6.00+ /sq. ft.

Durability

Less durable

More durable

Weather Issues

Softens in high heat

Cracks in freezing temperatures

Longevity

20 years+

40 years+

Maintenance

Resealing every 3-5 years

Sealing optional; occasional degreasing

Finishes

None

Multiple types

Colors

Primarily black

Multiple color options

Resurfacing

Yes

No

Repairs

Easy

Difficult

REINFORCED CONCRETE
Cements concrete is a mixture of cements, water, sand, crushed stone/gravel etc.,
Cements acts as a binder for sand and stone chips / gravels.
Concrete is a heterogeneous material characterized by a high compressive strength (28 4000
psi) but low tensile strength (2 350 psi).
When a concrete is bend the failure occur in the tension side of the member, resulting in crack in
the concrete mass. This is overcome with Steel in the form of rods, wires, bars or fabric embedded
in the fresh concrete.
If the tensile stress in steel bar exceeds the value of Compressive strength of concrete, the
concrete will develop a tensile crack. But this crack will not be detrimental, since the bond
between steel and concrete prevents the width of cracks from becoming significant. If the Width is
larger, then the concrete will become permeable to moisture and gases, then corrosion of the steel
reinforcement may occur.
The thermal expansion of steel is so close to that of concrete.
Adhesive bond between Steel-Cements is very strong and the steel is protected from corrosion by
the highly alkaline environment of the cement paste.
Adhesion can be improved by imparting special surface patterns that provide interlocking
between the cement paste and surface of the Steel.

Advantage of RCC
1. It is economical
2. Verry ductile and fire resistant
3. Maintanance of RCC Structures is negligible.
4. It is impermeable to mopisture penetration.
5. Different shapes can be obtained easily
6. RCC are not affected by vermins, fungus or other such insects.
7. RCC materials are easily available and abundance.

PRESTRESSED CONCRTE
RCC crack in the tensile regions when subjected to a relative small fraction of working load. To
make a better use for structural, prestressed concrete has been designed.
The PSC involves introduction of an internal compressive stress into a structure. Thus cracking in
tensile region is no longer inevitable in concrete structure and this make the materials more
resistant to chemical attack.
Prestressed concrete is designed so that the tensile cracks may be developed only at some
load greater than the working load.
Before the tensile stress occurs in the pre-stressed concrete, the preapplied compressive stresses
first must be counteracted or wiped out.
The precompression is usually obtained by two main methods
1. Pretensioning
2. Post tensioning

1. Rolls of post-tensioning cables

2. Pulling anchors for post-tensioning cables

3. Pulling anchors for post-tensioning cables

4. Pulling anchors for post-tensioning cables

5. Post-tensioning cables stripped for placement in pulling anchors

6. Positioned post-tensioning cables

7. Post-tensioning cable ends extending from freshly poured concrete

8. Post-tensioning cable ends extending from concrete slab

9. Hydraulic jack for tensioning cables

10. Cable conduits in formwork

In pre-tensioning, the prestress force is applied by means of high strength steel wire called
tendons, which arranged end to end between two fixed anchorages. Tendons are then stretched
to a high state and molds are filled with fresh concrete. After the concrete has hardened, the
tendons are released from the anchorages and concrete is then put into compression because
these tendons contract. The stress in tendon is transferred as Bonding stress.
Prestressed concrete is widely used in highways and railways bridges, pretension units for span
upto 15 m, for long span posttension construction is used.
Vessel and tanks are being prestressed by passing the tendons around them and there by
applying a uniform precompression to the vessel walls.

CONCRETE POLYMER COMPOSITES

Introduction of polymer meterials into concrete is rapidly expanding.
Following are the main clasess of CPC
1. Polymer impregnated concrete (CPC)
PCP, mortor and ceramics can be result in major improvement in mechanical strength, elastic
modules and impact resistance.
PCP involves incorporating of a suitable monomers into the pore structure of preformed cured
concrete or mortar and subsequently in-situ polymerize either by free radical mechanism or by
heat and pressure.
Step 1. Impregnating of mortars with monomers involves preparation of mortar by mixing
cements with sand in 1: 3 and using high water:cement ratio of 0.7 which after curing gives a
much porous materials that favors penetration of monomers.
Step 2. Then the material is dried and heated in under pressure to produce the polymer
impregnation.
Polymers may be incorporated in concrete in the following ways:
1. By adding a polmerizable monomers to fresh concrete or motor mix and then curing
concrete and monomers
2. By adding latex into fresh cements or cement mix and then curing the composition
in presence of polymers
3. By impregnating a crude mortar or concrete with a monomers using thermal or radiation
catalyst.
2. Pre-cast Polymer (PCP)
A pure quality silica sand of size 30-40 mesh is mixed with a polymeric binder such as epoxy,
methyl methacrylate and polyester.
Usually these resins are used as monomers which after mixing the sand and casting
are polymersized either by heat or by radiation.
The product has much improved properties compared to Portland cements combination but
the price is high.
Advantages of polymer concrete include:
Rapid curing at ambient temperatures
High tensile, flexural, and compressive strengths
Good adhesion to most surfaces
Good long-term durability with respect to freeze and thaw cycles

 Low permeability to water and aggressive solutions

Good chemical resistance
Good resistance against corrosion
Lighter weight (only somewhat less dense than traditional concrete, depending on the resin
content of the mix)
May be vibrated to fill voids in forms
Allows use of regular form-release agents (in some applications)
Dielectric
Disadvantage
Product hard to manipulate with conventional tools such as drills and presses due to
its strength and density.

FIBER REINFORCED CEMENTS

Cements offers great potential for fiber strengthening dur to its low modulus.
It shows significant strengthening and increased work of fracture by utilizing a veriety of
reinforcement asuch as metal wires, glass fiber, asbestors, carbin fibers and Al fibers.
The fiber limit the length of crack during the early stages of initiation from pre-exisitng flaws
to fibre ahead of crack tip opposing elastic displacement of the matix.
Polypropylene and Nylon fibers can:
Improve mix cohesion, improving pumpability over long distances
Improve freeze-thaw resistance
Improve resistance to explosive spalling in case of a severe fire
Improve impact resistance
Increase resistance to plastic shrinkage during curing
Steel fibers can:
Improve structural strength
Reduce steel reinforcement requirements
Improve ductility
Reduce crack widths and control the crack widths tightly, thus improving durability
Improve impact and abrasionresistance