A Brief Introduction to Composite Materials

COMPOSITE MATERIALS

Objective of the Capsule: What are composites Why do we need composites Typical Applications

COMPOSITE MATERIALS

A composite is any material made of more than one component

COMPOSITE MATERIALS

+ 4 + 5?
COMPOSITE MATERIALS 5

1.Composite?

2.Macintosh?
COMPOSITE MATERIALS 6

Macintosh

Why do we make composites? To make a material that has the properties of both its components.
We combine the water-resistance of Polyisoprene and the comfort of Cotton.
COMPOSITE MATERIALS 7

Composite
Fibre Matrix

COMPOSITE MATERIALS

Composite
Fiber
Glass / Kevlar / Carbon / PE
COMPOSITE MATERIALS

Matrix

TS/ Epoxy / Polyimide

Composites

Particle Based
Magneto Cover

Fibre Reinforced

COMPOSITE MATERIALS

10

Composites

Particle Based Laminar

Fibre Reinforced

e.g: FERAL, Plywood, ARAL,

COMPOSITE MATERIALS 11

Particulates:
Spheres Rods Flakes Aspect Ratio ~1

COMPOSITE MATERIALS

12

Composite Properties affected by: Size, Shape Amount & Distribution Modulus

COMPOSITE MATERIALS

13

Fiber Composites

Short Fiber Discontinuous

Long Fiber Continuous

Relationship between Modulus & Length

COMPOSITE MATERIALS 14

Particle Board

MDF Board

Plywood

Isotropy
(Random Particulate)

Properties Orthotropy
(Continuous Fiber)

Anisotropy
(Aligned Short fiber)

COMPOSITE MATERIALS

16

Cf Densities of Glass Vs Al
Floating?

FRP

Low weight of plastic (?)

Corrosion resistance of plastic (?) Tensile strength of glass fibers (?)
COMPOSITE MATERIALS 17

(?)

COMPOSITE MATERIALS

18

Fiber is embedded in the matrix in order to make the matrix stronger. Advantages of FRC

Strong and light

Stronger than steel, but weigh much less. Can be used to make automobiles lighter

More fuel efficient

Pollute less
COMPOSITE MATERIALS 19

What Fibers Do?

Fiber-reinforced composite= Fiberglas.

We pour a mix of the Styrene and Polyester over a mass of glass fibers The styrene and the double bonds in the polyester react by Polymerization to form a cross-linked resin Glass fibers are trapped inside, where they act as a reinforcement
COMPOSITE MATERIALS 20

In Fiberglas the fibers aren't lined up in any particular direction. They're just a tangled mass, like you see on the right.
We can make the composite stronger by lining up all the fibers in the same direction.
COMPOSITE MATERIALS 21

Any suggestion to make it strong in both directions?

COMPOSITE MATERIALS 22

COMPOSITE MATERIALS

23

What does the matrix do for the fiber? Why not just use fibers by themselves? 1.Function of Matrix Matrix holds the fibers together A loose bundle of fibers wouldn't be of much use.

COMPOSITE MATERIALS

24

2. Function of Matrix
Though fibers are strong, they can be brittle. The matrix can absorb energy by deforming under stress.(i.e) the matrix adds toughness to the composite.

COMPOSITE MATERIALS

25

// Example of the Sleeved Column

COMPOSITE MATERIALS

26

3.Function of Matrix While fibers have good tensile strength, they usually have low compressive strength That is, they buckle when you squash them The matrix gives compressive strength to the composite

COMPOSITE MATERIALS

27

Function of Matrix Surrounds fibers to form a continuous phase Transfers load to & between fibers

Protects Fibers from Environment

Protects from Damage during handling

Keeps fibers in proper orientation

Distributes load uniformly Gives resistance to crack propagation Provides inter-laminar shear strength
COMPOSITE MATERIALS 28

Why Glass Fiber?

Economical

As fiber, strong & flexible!

COMPOSITE MATERIALS

29

Glass Grade A E ECR S

Properties of Glass Fibers Sp. Tensile Tm Applications 0C Strength Gravity MPa

COMPOSITE MATERIALS

30

Glass Grade A E ECR S

Properties of Glass Fibers Sp. Tensile Tm Applications 0C Strength Gravity MPa 2.50
2.58 2.62 2.48

COMPOSITE MATERIALS

31

Glass Grade A E ECR S

Properties of Glass Fibers Sp. Tensile Tm Applications 0C Strength Gravity MPa 2.50 3040
2.58 2.62 2.48 3450 3625 4590

COMPOSITE MATERIALS

32

Glass Grade A E ECR S

Properties of Glass Fibers Sp. Tensile Tm Applications 0C Strength Gravity MPa 2.50 3040 996
2.58 2.62 2.48 3450 3625 4590 1065 1204 1454

COMPOSITE MATERIALS

33

Glass Grade A E ECR S

Properties of Glass Fibers Sp. Tensile Tm Applications 0C Strength Gravity MPa 2.50 3040 996 Good Chem. Resistance 2.58 3450 1065 Electrical Grade (PCB) 2.62 3625 1204 Elec.+ Chem.
2.48 4590 1454
Strength + Therm. Stability (Air-craft)
34

COMPOSITE MATERIALS

C Grade R Grade Coupling Agent Coating (Sizing Applicator) Imparts lubricity Resin Compatibility Dimensional Stability Adhesion with Matrix Protection from handling damage

Fire-Proof Kevlar West

Carbon fiber > Kevlar

Wrt UTS
COMPOSITE MATERIALS 36

Kevlar: Tends to be tougher Can absorb more energy without breaking Can stretch a little to keep from breaking, more so than carbon fiber can

Can withstand more force without breaking

Carbon-Kevlar
COMPOSITE MATERIALS 37

Spectra Strongest, lightest man-made fiber Bullet resistant composite

10 times stronger than steel

40 percent stronger than aramids Light enough to float on water Exhibits superior resistance to chemicals,Water and UV light

Excellent vibration dampening,flex fatigue and internal fiber-friction characteristics

COMPOSITE MATERIALS 38

Spectra fibers are used in

Police and military ballistic vests

Helmets and armored vehicles Sailcloth Fishing lines Cut-resistant gloves Safety apparel

COMPOSITE MATERIALS

39

20%

Reinforcement Particles / Fibers 80%

80% Matrix 20%

Continuums of Composites by Volume

COMPOSITE MATERIALS

40

Matrix needs only to wet & form a continuous phase around the reinforcement

COMPOSITE MATERIALS

41

Properties of Composites
Matrix Reinforcement Properties Improved
Mechanical Strength Elevated Temp. Strength Chemical Resistance Anti-static Electrical Resistance EMF Shielding Flexibility Wear Resistance Energy Absorption Thermal Stability
42

Thermosets Carbon Thermoplasts Glass Organic Fiber Glass Bead Ceramic Particle Metal wire

COMPOSITE MATERIALS

Classification Based on Material of Matrix:

Metal Ceramic Polymer

COMPOSITE MATERIALS

43

Metal Composites:
Continuous metallic phase (the matrix) + another phase (the reinforcement) To give desired properties

Example: Feral

COMPOSITE MATERIALS

44

Classification Based on Form of Reinforcement:

Particulate Fiber Laminar

COMPOSITE MATERIALS

45

Applications of Composites

COMPOSITE MATERIALS

46

Mag - Graphite Composite Tennis Racquet

COMPOSITE MATERIALS

47

COMPOSITE MATERIALS

48

Should be As light as possible As strong as possible Can bend but should not break

COMPOSITE MATERIALS

49

SwRI-developed low-flammability formulations are used in fabricating highstrength and lightweight honeycombs and foams for aircraft, marine, and automotive applications.
COMPOSITE MATERIALS 50

Polymer Composite Bridge Capability?

COMPOSITE MATERIALS

51

Fiber Reinforced Polymer (FRP) Composite Bridge Technology

COMPOSITE MATERIALS 52

COMPOSITE MATERIALS

53

SERC, Taramani, Chennai

Unmanned Islands Railway Sleepers
Old Design

Modern Design 1970

COMPOSITE MATERIALS

54

Applications:
Carbon fiber reinforced Composite first created in 1963

By the 1970s "graphite" composites of carbon fiber and epoxy were replacing up to three-quarters of the mass of jet fighter aircraft

COMPOSITE MATERIALS

55

COST OF CARBON FIBER in US $ / kg

250 200 150 100 50 0 1970s 1980s

220

COMPOSITE MATERIALS

56

First Flight :4 January 2001

Crew one, pilot

Maximum speed:1.8 Mach Range:850 km Service ceiling:15,250 m Length:13.20 m

LCA Tejas

Wingspan:8.20 m Height:4.40 m Weights

Empty:5,500 kg
Loaded:8,500 kg
COMPOSITE MATERIALS 57

Problem with Crucible:

Cracking

Analysis
Caused by uneven heating at high temperatures Any suggestion to make Heating uniform?
COMPOSITE MATERIALS 58

Solution:

Metal Ceramic Composite Crucible Metal inlay to distribute heat uniformly throughout the crucible. (The inlay heats up first, then heats the rest of the crucible.)(How?) Generally speaking you cannot solve a technical problem w/o.
COMPOSITE MATERIALS 59

Problem caused by metal Inlay:

Cracking caused by expansion of the metal inlay Robust Design?

Metal Ceramic Composite Crucible

COMPOSITE MATERIALS 60

Final Solution: Special coating to the ceramic to serve as a shock absorber This innovation allowed the metal inlay to expand without cracking the crucible

Metal Ceramic Composite Crucible

Award winning Design

COMPOSITE MATERIALS

61

Conclusion:
Generally Composites are characterized by: 1. Density 2. Specific strength 3. Specific Stiffness 4. High-temperature performance limits 5. Wear resistance

COMPOSITE MATERIALS

62

Aircraft Speed
Drag Force Skin Temperature

COMPOSITE MATERIALS

63

Relationship between weight & cost?

Cost

?
Weight
COMPOSITE MATERIALS 64

Relationship between weight & cost?

Cost

Aero Space

Automotive

Weight
COMPOSITE MATERIALS 65

Think Composites

COMPOSITE MATERIALS

66

THANK YOU
COMPOSITE MATERIALS 67