Teknologi

Komposit
Classification of Artificial
Composites
Composites

Particulate Fiber Structural

Large Dispersion Laminates Sandwich

Particle Strengthened Panels
Continuous Discontinuous

Aligned Random
 Properties of Composites
Dependent on:
constituent phases
relative amounts
geometry of dispersed phase
shape of particles
particle size
particle distribution
particle orientation
Forms of Reinforcement Phase
Fibers
cross-section can be circular, square or hexagonal
Diameters --> 0.0001 - 0.005
Lengths --> L/D ratio
100 -- for chopped fiber
much longer for continuous fiber
Particulate
small particles that impede dislication movement (in metal
composites) and strengthens the matrix
For sizes > 1 mm, strength of particle is involves in load
sharing with matrix
Flakes
flat platelet form
Reinforcement - Partikel
Advantages:
Kekuatan lebih seragam pada berbagai arah
Dapat digunakan untuk meningkatkan kekuatan dan
meningkatkan kekerasan material
Cara penguatan dan pengerasan oleh partikulat
adalah dengan menghalangi pergerakan dislokasi
Reinforcement - Partikel
Large particle komposit
Komposit yang disusun oleh reinforce berbentuk
partikel, dimana interaksi antara partikel dan matrik
terjadi tidak dalam skala atomik atau molekular.
Reinforcement - Partikel
Contoh large partikel komposit :
1.Sphereodite steel (cementite sebagai partikulat)
2.Tire (carbon sebagai partikulat)
3.Oxide-Base Cermet (oksida logam sebagai partikulat)
Reinforcement - Partikel
Dispersion strengthened komposit:
Fraksi partikulat sangat kecil, jarang lebih dari 3%.
Ukuran yang lebih kecil yaitu sekitar
10-250 nm.
Reinforcement - Partikel
FABRIKASI:
Metalurgi Serbuk
Stir Casting
Infiltration Process
Spray Deposition
In-Situ Process
CERMET Cutting Tool

Light phase - Matrix (Cobalt)

Dark phase- Particulate (WC)

Figure 16.7 Microstructure of an aluminum casting alloy reinforced with
silicon carbide particles. In this case, the reinforcing particles have
segregated to interdendritic regions of the casting ( 125).
(Courtesy of David Kennedy, Lester B. Knight Cost Metals Inc.)
 Fiber Material Properties

Steel: density (Fe) = 7.87 g/cc; TS=0.380 GPa; Modulus=207 GPa

Al: density=2.71 g/cc; TS=0.035 GPa; Modulus=69 GPa
Fiber Strength
Specific Material Properties:
Bila dibandingkan dengan engineering materials yang lain,
FRPs sangat competitive ditinjau dari beratnya
Density Stiffness Tensile
Specific Specific
r E Strength
Stiffness Strength
(Gpa) s E/r
(kg/m3) s/r
(Mpa)
Mild Steel 7800 208 400 1 1
Aluminium 2700 70 200 0.97 1.44
Nylon 1100 2.5 80 0.09 1.42
Concrete 2400 40 20 0.63 0.16
Random Fibre FRP 1800 20 300 0.42 3.25
Alligned Fibre FRP
(Load // Fibres) 1600 200 1500 4.69 18.3
(Load Fibres) 1600 3 50 0.07 0.61
 Reinforcement material
Type of reinforcing materials:
Fiberglass Glass Fiber Reinforced Polymers
Carbon Fiber Reinforced Polymer
Kevlar (aramid) Fiber Reinforced Polymer
Typical arrangement of the fiber material:
Unidirectional fibers
Roving
Veil mat: thin pile of randomly oriented and
looped continuous fiber
Chopped strands: thin pile of randomly oriented
and looped short fiber
Woven fabrics
 Reinforcement material

Above Left: Roving

Above Right: Filaments
Right: Close up of a roving
Reinforcement material

Random mat and woven fabric (glass fibers)

 Reinforcement material

Carbon fiber woven fabric

Fibers - Glass
Most widely used fiber
Uses: piping, tanks, boats, sporting goods
Advantages
low cost
Corrosion resistance
Low cost relative to other composites:
Disadvantages
Relatively low strength
High elongation
Moderate strength and weight
Types:
E-Glass - electrical, cheaper
S-Glass - high strength
Glass Fiber Reinforced Composite
Glass is widely used as reinforcing material due to
its properties
Readily available and inexpensive material
Simple and inexpensive to prepare from molten glass
High tensile strength
High corrosion resistance
Type of glass for fiberglasses
E-glass most popular and inexpensive glass. (E stands
for electrical. E-glass is excellent insulator)
S-glass stronger than E-glass. (S stands for strength)
S+R-glass the strongest and most expensive glass fibers
C-glass corrosion and chemical resistance glass fibers
Glass Fiber Reinforced Composite
Characteristics of GFRP
High strength-to-weight ratio
High modulus of elasticity-to-weight ratio
Good corrosion resistance
Good insulating properties
Low thermal resistance
Typical applications of GFRP
Marine structures
Automotive and truck body panels
Pressure vessels
Aircraft wing and fuselage sections
Fibers - Carbon
2nd most widely used fiber
Examples
aerospace, sporting goods
Advantages
high stiffness and strength
Low density
Intermediate cost
Properties:
Standard modulus: 207-240 Gpa
Intermediate modulus: 240-340 GPa
High modulus: 340-960 GPa
Diameter: 5-8 microns, smaller than human hair
Fibers grouped into tows or yarns of 2-12k fibers
Fibers -- Carbon
Types of carbon fiber
vary in strength with processing
Trade-off between strength and modulus
Intermediate modulus
PAN (Polyacrylonitrile)
fiber precursor heated and stretched to align structure and
remove non-carbon material
High modulus
made from petroleum pitch precursor at lower cost
much lower strength
Carbon Fiber Reinforced Composite
Carbon fibers are used due to following characteristics
Very high modulus of elasticity, exceeding that of steel
High tensile strength
Low density
High chemical inertness
Type of carbon fibers:
UHM (ultra high modulus). Modulus of elasticity > 65400 ksi
(450GPa).
HM (high modulus). Modulus of elasticity is in the range 51000-
65400 ksi (350-450GPa).
IM (intermediate modulus). Modulus of elasticity is in the range
29000-51000 ksi (200-350GPa).
HT (high tensile, low modulus). Tensile strength > 436 ksi (3
GPa), modulus of elasticity < 14500 ksi (100 GPa).
SHT (super high tensile). Tensile strength > 650 ksi (4.5GPa).
Carbon Fiber Reinforced Composite
Characteristics of CFRP
Light weight;
High strength-to-weight ratio;
Very High modulus elasticity-to-weight ratio;
High fatigue strength;
Good corrosion resistance;
Very low coefficient of thermal expansion
Low impact resistance
High electric conductivity;
High cost
Typical applications of CFRP
Automotive, marine and aerospace parts
Sporting goods
Fibers - Aramid (kevlar, Twaron)
Uses:
high performance replacement for glass fiber
Examples
Armor, protective clothing, industrial, sporting goods
Advantages:
higher strength and lighter than glass
More ductile than carbon
Kevlar Fiber Reinforced Composite
Kevlar fibers possess following properties:
High tensile strength (five times stronger per
weight unite than steel);
High modulus of elasticity
Very low elongation up to breaking point;
Low weight;
High chemical inertness;
Very low coefficient of thermal expansion
High Fracture Toughness (impact resistance);
High cut resistance;
Textile processibility;
Flame resistance.
Kevlar Fiber Reinforced Composite
Several modifications of Kevlar
Kevlar 29 high strength (520000 psi/3600 MPa), low
density (90 lb/ft/1440 kg/m) fibers used for
manufacturing bullet-proof vests, composite armor
reinforcement, helmets, ropes, cables, asbestos replacing
parts.
Kevlar 49 high modulus (19000 ksi/131 GPa), high
strength (550000 psi/3800 MPa), low density (90
lb/ft/1440 kg/m) fibers used in aerospace, automotive
and marine applications.
Kevlar 149 ultra high modulus (27000 ksi/186 GPa),
high strength (490000 psi/3400 MPa), low density (92
lb/ft/1470 kg/m) highly crystalline fibers used
as reinforcing dispersed phase for composite aircraft
components.
Fibers - Others
Boron
High stiffness, very high cost
Large diameter - 200 microns
Good compressive strength
Polyethylene - trade name: Spectra fiber
Textile industry
High strength
Extremely light weight
Low range of temperature usage
Fibers -- Others
Ceramic Fibers (and matrices)
Very high temperature applications (e.g. engine
components)
Silicon carbide fiber - in whisker form.
Ceramic matrix so temperature resistance is not
compromised
Infrequent use
Comparative Cost of Fiber
Reinforcement
MATRIX------?
Merupakan fasa pada komposit yang menjadi
bagian penting.
Unsur / fasa terbanyak pada komposit
Dapat menentukan jenis komposit
Jumlah v/v nya lebih besar
MATRIX
Fungsi dari matrik pada komposit adalah :
Mentransfer tegangan ke serat.
Menginfiltrasi serat dan cepat membeku.
Membentuk ikatan koheren, permukaan
matrik/serat.
Melindungi serat.
Memisahkan serat.
Tetap stabil setelah proses manufaktur.
Matrix Materials
Functions of the matrix
Transmit force between fibers
arrest cracks from spreading between fibers
do not carry most of the load
hold fibers in proper oreintation
protect fibers from environment
mechanical forces can cause cracks that allow environment to
affect fibers
Demands on matrix
Interlaminar shear strength
Toughness
Moisture/environmental resistance
Temperature properties
Cost
MATRIX
Polimer Matrix: Composite yang berupa
polimer yang diperkuat (PMC)

Metal Matrix : Composite yang berupa

metal sebagai matriknya (MMC)

Ceramic Metrix : Composite yang berupa

ceramic sebagai matriknya (CMC)
Types of Composites
Matrix Metal Ceramic Polymer
phase/Reinforc
ement Phase
Metal Powder metallurgy Cermets (ceramic- Brake pads
parts combining metal composite)
immiscible metals

Ceramic Cermets, TiC, TiCN SiC reinforced Fiberglass

Cemented carbides Al2O3
used in tools
Fiber-reinforced
Tool materials
metals

Polymer Kevlar fibers in an

epoxy matrix

Elemental Fiber reinforced Rubber with

(Carbon, metals carbon (tires)
Auto parts Boron, Carbon
Boron, etc.)
aerospace reinforced plastics

MMCs CMCs PMCs

Metal Matrix Composites Ceramic Matrix Comps. Polymer Matrix Comps
Polymer Matrix Materials
Thermosets
cure by chemical reaction
Irreversible
Examples
Polyester, vinylester
Most common, lower cost, solvent resistance
Epoxy resins
Superior performance, relatively costly
Polymer Matrix Materials
Thermoplastics
Formed by heating to elevated temperature at which
softening occurs
Reversible reaction
Can be reformed and/or repaired - not common
Limited in temperature range to 150C
Examples
Polypropylene
with nylon or glass
can be injected-- inexpensive
Soften layers of combined fiber and resin and place in a mold
-- higher costs
Manufacturing of Glass fiber
Matrix - Others
Metal Matrix Composites - higher temperature
e.g., Aluminum with boron or carbon fibers
Ceramic matrix materials - very high temperature
Fiber is used to add toughness, not necessarily higher in
strength and stiffness
Important Note

Composite properties are less than that

of the fiber because of dilution by the
matrix and the need to orient fibers in
different directions.
Composite Parameters
For a given matrix/dispersed phase
system:
Concentration
Size
Shape
Distribution
Orientation
 Parameters

Distribution Concentration Orientation

Shape Size
Costs of composite manufacture
Material costs -- higher for composites
Constituent materials (e.g., fibers and resin)
Processing costs -- embedding fibers in matrix
not required for metals Carbon fibers order of magnitude
higher than aluminum
Design costs -- lower for composites
Can reduce the number of parts in a complex assembly
by designing the material in combination with the
structure
Increased performance must justify higher material
costs
Material Forms and
Manufacturing
Objectives of material production
assemble fibers
impregnate resin
shape product
cure resin
Sheet Molding Compound (SMC)
Chopped glass fiber added to polyester resin mixture

Question: Is SMC isotropic or anisotropic?

Manufacturing - Filament Winding
Highly automated
low manufacturing costs if
high throughput
e.g., Glass fiber pipe,
sailboard masts
Prepregs
Prepreg and prepreg layup
prepreg - partially cured mixture of fiber and resin
Unidirectional prepreg tape with paper backing
wound on spools
Cut and stacked
Curing conditions
Typical temperature and pressure in autoclave is 120-200C, 100
psi
 Manufacturing - Layups

compression
molding

vacuum bagging
Material Forms

Textile forms
Braiding or weaving
Tubular braided form
can be flattened and cut for non-tubular
products
Fabric effects on material
properties
Resin transfer molding (RTM)
Dry-fiber preform placed in a closed mold, resin
injected into mold, then cured
Material Forms
Pultrusion
Fiber and matrix are pulled through a die,
like extrusion of metals -- assembles
fibers, impregnates the resin, shapes the
product, and cures the resin in one step.
Example. Fishing rods
Pultrusion
Manufacturing
Tube rolling - tubular products
Examples
fishing rods
golf clubs
oars
Prepreg tape typically used wrapped in 2 directions or
spiral wrapped
MANUFACTURING OF POLYMER-MATRIX COMPOSITES
Hand Lay-Up/Spray-Up
-Oldest and most commonly used manufacturing method
-Usually used to produce polyester or epoxy resin parts such as boat hulls,
tanks and vessels, pick-up truck canopies
-The method is quite simple, the resin and reinforcement is placed against
the surface of an open (one sided) mold and allowed to cure or in the case of
spray-up the resin/reinforcement is sprayed onto the mold with a spray gun

-Often a gel coat is applied to the mold prior to

produce a better surface quality and protect the
composite from the elements
-A gel coat is a resin usually 0.4 to 0.7 mm thick,
commonly seen on the outer surface of smaller
boats
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Hand Lay-Up/Spray-Up
-The pros of this process include: low initial start up cost, easy to change
mold/design, on-site production possible (ie portable process)
-The cons include: labor intensive, the quality of parts depends on operators
skill and therefore inconsistent, only one good side to the part
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Prepreg

-A pregreg (short for preimpregnated) is a composite that comes

with the resin already added to the reinforcement
-This means that the only concern when working with prepreg is
shaping the part
-Since the resin is already mixed (resin and catalyst) there is a
limited shelf life
-For the same reason prepreg must be cured in an oven or
autoclave
MANUFACTURING OF POLYMER-MATRIX COMPOSITES
Prepreg
-Prepreg can be used in a few different ways
-It can be placed against a mold similar to the hand lay-up method
-Once placed in the mold the material must be compressed and cured according to a specific
pressure/temperature cycle
-This is often done by means of a vacuum bag where a thin plastic cover is secured overtop of the
composite and the air is vacuumed out
-This process can reduce manufacturing time and produce a stronger part
(if a knitted preform is used)
-Another process used is automated tape lay-up
-This process uses a large automated roller similar to a packing tape roller
-The roller applies the tape with pressure which eliminates the need for a vacuum bag
- Automated tape lay-up is used to produce large parts, generally in aerospace applications and is
also capable of 3-d parts
MANUFACTURING OF POLYMER-MATRIX COMPOSITES
Pultrusion
-Similar to extrusion of metal parts
-Pultrusion involves pulling resin-impregnated glass strands through a die
-Standard extruded shapes can easily be produced such as pipes, channels, I-
beams, etc.
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Pultrusion
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Filament Winding
-A continuous reinforcement, either previously impregnated or impregnated during
winding is wound around a rotating mandrel to form a composite part

-Pros: fast lay-up speed, very accurate and repeatable product, possibility to use
continuous fiber

-Cons: expensive equipment, high cost for mandrel, poor surface finish, some
shapes not possible

-Examples: oxygen bottles for firemen, rocket motors, tennis rackets, shafts
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Filament Winding
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Filament Winding
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Resin Transfer Molding

-Resin transfer molding is a manufacturing method that is quite

similar to injection molding where plastic is injected into a
closed mold

-In the RTM process the preform (precut piece(s) of

reinforcement) is placed in the mold, the mold is closed and the
thermoset plastic matrix is injected into the mold, once the
matrix is cured the part is ejected
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Resin Transfer Molding

MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Resin Transfer Molding

Pros:
-Complex components can be produced
-Components have two good surfaces
-Component can be created within a fairly tight tolerance
-High level of repeatability
-Process can be automated and repeated
-Process can be numerically modeled and analyzed

Cons:
-Molds often need to be designed using trial and error methods
-race tracking may occur
-wash out may occur
-Air voids are easily formed with poor process parameters
MANUFACTURING OF POLYMER-MATRIX COMPOSITES

Resin Transfer Molding

Researcher from Aerospace Manufacturing Technology Center in

Montreal molding members for a helicopter