COMPOSITE MATERIALS

Pritish

Shubham
M-tech. (Mechanical) Roll- 10209007

COMPOSITE MATERIAL
Two inherently different materials that when combined together produce a material with properties that exceed the constituent materials.  A macroscopic mixture of two or more different materials.


COMPOSITES OFFER
High

Strength Light Weight Design Flexibility Consolidation of Parts Net Shape Manufacturing

COMPOSITES
A composite material consists of two phases: Primary y Forms the matrix within which the secondary phase is imbedded y Any of three basic material types: polymers, metals, or ceramics Secondary y Referred to as the imbedded phase or called the reinforcing agent y Serves to strengthen the composite. (fibers, particles, etc.) y Can be one of the three basic materials or an element such as carbon or boron

D E S I G N O B J E C T I VE :
Performance:

Strength, Temperature, Stiffness Manufacturing Techniques Life Cycle Considerations Cost

MATRIX CONSIDERATIONS :
End Use Temperature Toughness Cosmetic Issues Flame Retardant Processing Method Adhesion Requirements


THE MATRIX PHASE

Matrix material serves several functions in the composite y provides the bulk form of the part or product y holds the imbedded phase in place y shares the load with the secondary phase

T H E R E I N F O R CI N G P H A S E
The imbedded phase is most commonly one of the following shapes: Fibers Particles Flakes

T H E R E I N F O R CI N G P H A S E
Particles and Flakes  Particles Is an important material form for metals and ceramics range in size from microscopic (less than 1 micron) to macroscopic (greater than 1 micron) y In the microscopic size range and proportion of imbedded material of 15% or less, the particles result in strengthening the matrix y In the macroscopic size range and proportion of imbedded material of 25% or more, the particles serve to share the load with the matrix material. y This form of composite strengthening occurs in cemented carbides, in which tungsten carbide (80%) is held in a cobalt binder.

Flakes Basically, two-dimensional particles ranging 0.01 to 1.0 mm in across the flake, with a thickness of 0.001 to 0.005 mm


T H E R E I N F O R CI N G P H A S E
Fibers

Diameters range from .0001 in to about .005 in depending on the material. Generally circular in cross-section, but can also be in the form of tubular, rectangle, hexagonal. Fibers used can be either continuous or discontinuous y Continuous fibers are very long; in theory, they offer a continuous path by which a load Can be carried by the composite material y Discontinuous fibers are short lengths

T H E R E I N F O R CI N G P H A S E
Orientation of fibers is an important consideration. One-dimensional y maximum strength and stiffness are obtained in the direction of the fiber Planar y in the form of two-dimensional woven fabric Random or three-dimensional y the composite material tends to posses isotropic properties

T H E R E I N F O R CI N G P H A S E
Types of fabrics

Currently, the most common fibers used in composites are glass, graphite (carbon), boron and Kevlar 49. Glass most widely used fiber in polymer composites, the term fiberglass is applied to denote glass fiberreinforced plastic (GFRP) y E-glass strong and low cost, but modulus is less than other (500,000 psi) y S-glass stiffer and its tensile strength in one of the highest of all fiber materials (650,000 psi). Has about five times the tensile strength of steel and has a density of about one third that of steel
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T H E R E I N F O R CI N G P H A S E

Carbon are generally a combination of graphite. Graphite has a tensile strength three to five times stronger than steel and has a density that is one-fourth that of steel. Boron very high elastic modulus, but its high cost limits its application to aerospace components Ceramics Silicon carbide (SiC) and aluminum oxide (Al2O3) are the main fiber materials among ceramics. Both have high elastic moduli and can be used to strengthen lowdensity, low- modulus metals such as aluminum and magnesium Metal Steel filaments, used as reinforcing fiber in plastics
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C L A S SI FIC A T ION O F C O M P O S IT E
M A T E R IA L

Metal Matrix Composites (MMCs)

y

Include mixtures of ceramics and metals, such as cemented carbides and other cermets, as well as aluminum or magnesium reinforced by strong, high stiffness fibers

Ceramic Matrix Composites (CMCs)

y

Least common composite matrix. Aluminum oxid and silicon carbide are materials that can be imbedded with fibers for improved properties, especially in high temperature applications

Polymer Matrix Composites (PMCs)

y

Thermosetting resins are the most widely used polymers in PMCs. Epoxy and polyester are commonly mixed with fiber reinforcement

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M E T AL M AT RI X COM POS I T E S
Common reinforcing phase includes y Particles of ceramic (commonly called cermets) y Fibers of various materials, including other metals, ceramics, carbon, and boron

FRMMC combine the high tensile strength and modulus of elasticity of a fiber with metals of low density, thus achieving good strength-to-weight and modulus-to-weight ratios in the resulting composite material.

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M E T AL M AT RI X COM POS I T E S

Cutting tools are the most common application of cemented carbides based on tungsten carbide Titanium carbide cermets are used principally for high temperature applications. y Nickel is the preferred binder; its oxidation resistance at high temperature is superior to that of cobalt. y Used as a cutting tool material for machining steels.
Disadvantage Low toughness and bulk tensile strength Susceptibility to thermal cracking
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Advantage High stiffness Hardness Hot hardness Compressive strength Relatively low density

CERAMIC MATRIX COMPOSITES

Ceramic matrix composites represent an attempt to retain the desirable properties of ceramics while compensating for their weakness. Ceramic materials used as matrices includes: y Alumina y Boron carbide y Boron nitride y Silicon carbide y Silicon nitride y Titanium carbide
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POLYMER MATRIX COMPOSITES

The most important of the three classes of synthetic composites. FRP are most closely identified with the term composite. FRP A composite material consisting of a polymer matrix imbedded with high-strength fibers. Widely used in rubber products such as tires and conveyor belts. Principle fiber materials are: glass, carbon, and Kevlar 49 with glass (E-glass) the most common fiber material
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POLYMER MATRIX COMPOSITES

Advanced

composites use boron, carbon, Kevlar as the reinforcing fibers with epoxy as the common matrix polymer.

Hybrids When two or more fibers materials are combined in the composite. y Intraply hybrids (within) - Alternate strands of different fibers in a single layer or ply y Interply hybrid (across) Different plies of different fibers
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POLYMER MATRIX COMPOSITES Attractive features of FRP: y high strength-to-weight ratio y high modulus-to-weight ratio y low specific gravity y good fatigue strength y good corrosion resistance, although polymers are soluble in various chemicals y low thermal expansion, leading to good dimensional stability y significant anisotropy in properties

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COMPOSITE MANUFACTING PROCESS

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S HAPI N G PROCE S S E S FOR POL YM E R M AT RI X COM POS I T E S

Some of the methods for making polymeric composites are as following:1.

2.

3.

4.

Open Mold Processes- the original FRP manual procedures for laying resins and fibers onto forms Closed Mold Processes- same as those used in plastic molding Filament Winding- continuous filaments are dipped in liquid resin and wrapped around a rotating mandrel, producing a rigid, hollow, cylindrical shape Pultrusion Processes- similar to extrusion only adapted to include continuous fiber reinforcement 19

PM C S H A P E P R O C E S S I N G
Many

PMC shaping processes are slow and labor intensive In general, techniques for shaping composites are less efficient than for other materials y Composites are more complex than other materials, consisting of two or more phases y For FRPs, there is the need to orient the reinforcing phase

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Classification of FRP Processes

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TRANSFER MOLDING COMPOUNDS

FRP composite molding compounds consist of the resin matrix with short randomly dispersed fibers, similar to those used in plastic molding Most molding compounds for composite processing are thermosetting polymers Since they are designed for molding, they must be capable of flowing y Accordingly, they have not been cured prior to shape processing y Curing is done during and/or after final shaping
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Fibers impregnated with partially cured TS resins to facilitate shape processing Available as tapes or cross-plied sheets or fabrics Curing is completed during and/or after shaping Advantage: prepregs are fabricated with continuous filaments rather than chopped random fibers, thus increasing strength and modulus

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OPEN MOLD PROCESSES

Family of FRP shaping processes that use a single positive or negative mold surface to produce laminated FRP structures The starting materials (resins, fibers & mats) are applied to the mold in layers, building up to the desired thickness This is followed by curing and part removal Common resins are unsaturated polyesters and epoxies, using fiberglass as the reinforcement

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O P E N M O L D FRP P R O C E S S E S
1. 2. 3.

4.

Hand lay-up Spray up Vacuum Bagging uses hand-lay-up, uses atmospheric pressure to compact laminate. Automated tape-laying machines The differences are in the methods of applying the laminations to the mold, alternative curing techniques, and other differences

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HAND L AY-UP METHOD

Open mold shaping method in which successive layers of resin and reinforcement are manually applied to an open mold to build the laminated FRP composite structure Labor-intensive Finished molding must usually be trimmed with a power saw to size outside edges Oldest open mold method for FRP laminates, dating to the 1940s when it was first used for boat hulls

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Hand Lay-Up Method

Figure 15.4 Hand lay-up : (1) mold is treated with mold release agent; (2) thin gel coat (resin) is applied, to the outside surface of molding; (3) when gel coats are partially set, layers of resin and fiber are applied, the fiber is in the form of mat or cloth; each layer is rolled to impregnate the fiber with resin and remove air; (4) part is cured; (5) fully hardened part is removed from mold. 27

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PRODUCTS MADE BY HAND L AY-UP

Generally large in size but low in production quantity - not economical for high production Applications: y Boat hulls y Swimming pools y Large container tanks y Movie and stage props y Other formed sheets The largest molding ever made was ship hulls for the British Royal Navy: 85 m (280 ft) long

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SPRAY-UP METHOD
Liquid resin and chopped fibers are sprayed onto an open mold to build successive FRP laminations Attempt to mechanize application of resin-fiber layers and reduce lay-up time Alternative for step (3) in the hand lay-up procedure

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PRODUCTS MADE BY SPRAY-UP

Boat hulls, bathtubs, shower stalls, automobile and truck body parts, recreational vehicle components, furniture, large structural panels, and containers Movie and stage props are sometimes made by this method Since products made by spray-up have randomly oriented short fibers, they are not as strong as those made by lay-up, in which the fibers are continuous and directed

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VACUUM BAGGING

Use atmospheric pressure to suck air from under vacuum bag, to compact composite layers down and make a high quality laminate. Layers from bottom include: mold, mold release, composite, 32 peel-ply, breather cloth, vacuum bag, also need vacuum valve, sealing tape.

CURING IN OPEN MOLD PROCESSES

Curing is required of all thermosetting resins used in FRP laminated composites Curing cross-links the polymer, transforming it from its liquid or highly plastic condition into a hardened product Three principal process parameters in curing: 1. Time 2. Temperature 3. Pressure

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CLOSED MOLD PROCESSES

Performed in molds consisting of two sections that open and close each molding cycle Tooling cost is more than twice the cost of a comparable open mold due to the more complex equipment required in these processes Advantages of a closed mold are: (1) good finish on all part surfaces, (2) higher production rates, (3) closer control over tolerances, and (4) more complex three-dimensional shapes are possible

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C LASSIFICATION OF CLOSED MOULD

Three classes based on their counterparts in conventional plastic molding: 1. Compression molding 2. Transfer molding 3. Injection molding The terminology is often different when polymer matrix composites are molded
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F I L A ME N T W I N D I N G
Resin-impregnated continuous fibers are wrapped around a rotating mandrel that has the internal shape of the desired FRP product; the resin is then cured and the mandrel removed The fiber rovings are pulled through a resin bath immediately before being wound in a helical pattern onto the mandrel The operation is repeated to form additional layers, each having a criss-cross pattern with the previous, until the desired part thickness has been obtained

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Filament Winding

Figure 15.8 Filament winding.

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Filament Winding Machine

Figure 15.10 Filament winding machine (photo courtesy of Cincinnati Milacron).

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P ULTRUSION P ROCESSES
Similar to extrusion (hence the name similarity) but work piece is pulled through die (so prefix "pul-" in place of "ex-") Like extrusion, pultrusion produces continuous straight sections of constant cross section Developed around 1950 for making fishing rods of glass fiber reinforced polymer (GFRP) A related process, called pulforming, is used to make parts that are curved and which may have variations in cross section throughout their lengths
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PULTRUSION
Continuous fiber rovings are dipped into a resin bath and pulled through a shaping die where the impregnated resin cures The sections produced are reinforced throughout their length by continuous fibers Like extrusion, the pieces have a constant cross section, whose profile is determined by the shape of the die opening The cured product is cut into long straight sections
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Pultrusion Process

Figure 15.11 Pultrusion process

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M A T E RI ALS A N D P R O D U C T S I N PULTRUSION
Common

resins: unsaturated polyesters, epoxies, and silicones, all thermosetting polymers Reinforcing phase: E-glass is most widely, in proportions from 30% to 70% Products: solid rods, tubing, long flat sheets, structural sections (such as channels, angled and flanged beams), tool handles for high voltage work, and third rail covers for subways.
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CONCLUSIONS
 Composite materials offer endless design options.  Matrix, Fiber and Preform selections are critical in the design process.  Structures can be produced with specific properties to meet end use requirements.

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