Polymer

Composites

P.E. 406 Polymer Composites

 Contents

Conventional Engineering Materials

Introduction to Polymer Composites

Classification of Polymer Composites

Characteristics of Polymer
Composites

Applications of Polymer Composites

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P.E. 406 Polymer Composites

 Conventional
Engineering Materials
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P.E. 406 Polymer Composites

 Conventional Engineering
Materials


 There are more than 60,000 materials available to

engineers for the design and manufacturing of
products for various applications.
 Due to the wide choice of materials, today’s
engineers are posed with a big challenge for the
right selection of a material and the right
selection of a manufacturing process for a
particular application.

P.E. 406 Polymer Composites

 Broad Classification
of Materials
 These materials, depending on their major
characteristics (e.g., stiffness, strength,
density, and melting temperature), can be
broadly divided into four main categories:
1.Metals
2.Plastics
3.Ceramics
4.Composites
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P.E. 406 Polymer Composites

 Typical Properties of
Some Engineering Materials

P.E. 406 Polymer Composites

 Typical Properties of
Some Engineering Materials

P.E. 406 Polymer Composites

 Metals
 Dominating materials for structural uses
 Provide the largest design and processing
history
 The common metals are iron, aluminum,
copper, magnesium, zinc, lead, nickel, and
titanium.
 Through the principle of alloying, thousands
of new metals are created.

P.E. 406 Polymer Composites

 Metals
 Metals are, in general, heavy as compared to
plastics and composites.
 Metals have high stiffness, strength, thermal
stability, and thermal & electrical conductivity.
 Due to their higher temperature resistance than
plastics, they can be used for applications with
higher service temperature requirements.

P.E. 406 Polymer Composites

 Plastics
 Most common engineering materials over the past
two decades.
 In the past 5 years, the production of plastics on a
volume basis has exceeded steel production.
 Due to their light weight, easy processability, and
corrosion resistance, plastics are widely used for
automobile parts, aerospace components, and
consumer goods.

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P.E. 406 Polymer Composites

 Plastics
 With the help of a manufacturing process,
plastics can be formed into near-net-shape
or net-shape parts.
 They can provide high surface finish and
therefore eliminate several machining
operations.
 This feature provides the production of low-
cost parts.

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P.E. 406 Polymer Composites

 Plastics
 Not used for high-temperature applications
because of their poor thermal stability.
 The operating temperature for plastics is less than
100°C. (Some plastics can take service
temperature in the range of 100 to 200°C
without a significant decrease in the
performance)
 Plastics have lower melting temperatures than
metals and therefore they are easy to process.

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P.E. 406 Polymer Composites

 Plastic Items

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P.E. 406 Polymer Composites

 Ceramics
 Have strong covalent bonds and therefore provide
great thermal stability and high hardness.
 Technically they are inorganic non-metallic
materials which are formed by the action of heat
 Ceramics have the highest melting points of
engineering materials
 Most rigid of all materials

 Possess almost no ductility, so fail in brittle

fashion

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P.E. 406 Polymer Composites

 Ceramics
 Generally used for high-temperature and high-
wear applications and are resistant to most
forms of chemical attack.
 Require high-temperature for fabrication.

 Difficult to machine

 Require expensive cutting tools, such as carbide

and diamond tools.

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P.E. 406 Polymer Composites

 Ceramic

Items

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P.E. 406 Polymer Composites

 Composites
 Historically they are old but in 1960
composites start capturing the attention of
industries with the introduction of
polymeric-based composites.
 Common applications include:
 automotive components
 sporting goods
 aerospace parts
 consumer goods
 marine industries
 oil industries
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P.E. 406 Polymer Composites

 Composites
 Increased awareness regarding product
performance and increased competition in
the global market for lightweight
components fueled their growth.
 Among all materials, composite materials
have the potential to replace widely used
steel and aluminum, and many times with
better performance.

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P.E. 406 Polymer Composites

 Composites
 Polymer composite components can save:
 60 to 80% in component weight by replacing
steel components
 20 to 50% weight by replacing aluminum
parts
Ø
Ø Today, it appears that composites are the
materials of choice for many engineering
applications and Polymer-based Composites
are important than all other types.


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P.E. 406 Polymer Composites

 COMPOSITES’  ITEMS

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P.E. 406 Polymer Composites

 COMPOSITES’  ITEMS

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P.E. 406 Polymer Composites

 Polymer
Composites

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P.E. 406 Polymer Composites

 Composites - General Definition
 A composite material is made by combining two
or more materials to give a unique combination
of improved properties, such that each
component retains its physical identity.
 Composite obey the “principle of combined action”,
i.e; the mixture gives “averaged” properties.
 The above definition is more general and can
include metals alloys, plastic co-polymers,
minerals, and wood.


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P.E. 406 Polymer Composites

 Polymer Composites
 Fiber-reinforced polymer composite materials
differ from the above materials in that the
constituent materials are different at the
molecular level and are mechanically
separable.
 In bulk form, the constituent materials work
together but remain in their original forms.
 The final properties of composite materials
are better than constituent material
properties.

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P.E. 406 Polymer Composites

 Composite Examples in Nature
 Wood is a composite of cellulose fibers in a
matrix of natural glue called lignin.
 Husks or straws mixed with clay for house
building
 The shell of snails and oysters

 Human nails

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P.E. 406 Polymer Composites

 Formation of Composite Materials
 The main concept of a composite is that it
contains reinforcing material in a matrix
material.
 Typically, polymer composite material is
formed by reinforcing fibers in a matrix
resin.
Ø The reinforcements can be fibers, particulates,
or whiskers
Ø The matrix materials can be metals, plastics,
or ceramics.

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P.E. 406 Polymer Composites

 Formation of Composite Materials

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P.E. 406 Polymer Composites

 Formation of Composite Materials
 The reinforcements can be made from
polymers, ceramics, and metals.
 The fibers can be continuous, long, or short.

 Composites made with a polymer matrix

have become more common and are widely
used in various industries.
 They can be thermoset or thermoplastic
resins.


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P.E. 406 Polymer Composites

 Polymer Composites
 The reinforcing fiber or fabric provides strength
and stiffness to the composite, whereas the
matrix gives rigidity by transferring stress and
environmental resistance.
 Reinforcing fibers are found in different forms,
from long continuous fibers to woven fabric to
short chopped fibers and mat.
 Each configuration results in different properties.

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P.E. 406 Polymer Composites

 Continuous & Short Fiber Composites
 The properties strongly depend on the way
the fibers are laid in the composite.
 The important thing to remember about
composites is that the fiber carries the load
and its strength is greatest along the axis
of the fiber.
 Long continuous fibers in the direction of the
load result in a composite with properties
far exceeding the matrix resin itself. The
same material chopped into short lengths
yields lower properties than continuous
fibers. 30

P.E. 406 Polymer Composites

 Continuous & Short Fiber Composites

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P.E. 406 Polymer Composites

 Continuous & Short Fiber Composites
 Depending on the type of application
(structural or nonstructural) and
manufacturing method, the fiber form is
selected.
 For structural applications, continuous fibers
or long fibers are recommended; whereas
for nonstructural applications, short fibers
are recommended.

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P.E. 406 Polymer Composites

 Functions of Fibers and Matrix

 Both reinforcements (fibers mostly) and matrix

are complimentary to each other.
 They use each other’s properties in such a
manner that overall properties of the
composites are improved.

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P.E. 406 Polymer Composites

 Functions of Fibers
 To carry the load. In a structural composite,
70 to 90% of the load is carried by fibers.
 To provide stiffness, strength, thermal
stability, and other structural properties in
the composites.
 To provide electrical conductivity or
insulation, depending on the type of fiber
used.


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P.E. 406 Polymer Composites

 Functions of Matrix
 The matrix material binds the fibers together
and transfers the load to the fibers. It
provides rigidity and shape to the structure.
 The matrix isolates the fibers so that
individual fibers can act separately. This
stops or slows the propagation of a crack.
 The matrix provides a good surface finish
quality to the polymer composite.

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P.E. 406 Polymer Composites

 Functions of Matrix
 The matrix provides protection to reinforcing fibers
against chemical attack and mechanical damage
(wear).
 Depending on the matrix material selected,
performance characteristics such as ductility,
impact strength, etc. are also influenced. A ductile
matrix will increase the toughness of the
structure.
 The failure mode is strongly affected by the type of
matrix material used in the composite as well as
its compatibility with the fiber.
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P.E. 406 Polymer Composites

 Interface
 An interface is the surface formed by:
a common boundary of reinforcing fiber and
supporting matrix that is in contact with each
constituent
 maintains the bond in between for the transfer
of loads
 “An interface is the region of significantly
changed chemical composition that constitutes
the bond between the matrix and the
reinforcement”.
Ø
Ø It has physical and mechanical properties that 37
are unique from those of the fiber or the
P.E. 406 matrix. Polymer Composites
 Interphase
 “Geometrical surface of the classic fiber-matrix
contact as well as the (transition) region of finite
volume extending therefrom, wherein the
chemical, physical and mechanical properties
vary either continuously or in a stepwise manner
between those of the bulk fiber and the matrix
material.”
 In other words, the interphase exists in some
terminal point in the fiber, passes through the
actual interface and enters the matrix,
embracing all the volume altered during the
consolidation or fabrication process from the
original fiber and matrix materials.
Ø
38
Ø Interface is specific to each fiber-matrix
P.E. 406 system. Polymer Composites
 Interface - Schematic Diagram

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P.E. 406 Polymer Composites

 Classification
of
Polymer Composites
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P.E. 406 Polymer Composites

 Matrix


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P.E. 406 Polymer Composites

 Reinforcement


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P.E. 406 Polymer Composites

 Reinforcement


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P.E. 406 Polymer Composites

 Reinforcement


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P.E. 406 Polymer Composites

 Reinforcement


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P.E. 406 Polymer Composites

 Reinforcement



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 "Whiskers" are very strong because they don't contain
defects,
P.E. 406 i.e., notch sensitivity is eliminated
Polymer because there
Composites
 Reinforcement

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P.E. 406 Polymer Composites

 Reinforcement


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P.E. 406 Polymer Composites

 Reinforcement

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P.E. 406 Polymer Composites

 Reinforcement


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P.E. 406 Polymer Composites

 Reinforcement

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P.E. 406 Polymer Composites

 Reinforcement

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P.E. 406 Polymer Composites

 Reinforcement


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P.E. 406 Polymer Composites

 Reinforcement

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P.E. 406 Polymer Composites

 Reinforcement

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P.E. 406 Polymer Composites

 Reinforcement

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P.E. 406 Polymer Composites

 Composite Benefits

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P.E. 406 Polymer Composites

 Summary
Ø Composites are classified according to:
 --the matrix material (CMC, MMC, PMC)
 --the reinforcement geometry (particles, fibers,
layers).
 Composites enhance matrix properties:
 --MMC: enhance σy, TS, creep performance
 --CMC: enhance Kc
 --PMC: enhance E, σy, TS, creep performance
 Structural:
 --Based on build-up of sandwiches in layered form.

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P.E. 406 Polymer Composites

 Summary
 Particulate-reinforced:
 --Elastic modulus can be estimated.
 --Properties are isotropic.
 Fiber-reinforced:
 --Elastic modulus and TS can be estimated
along fiber direction.
 --Properties can be isotropic or anisotropic
depending upon alignment.


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P.E. 406 Polymer Composites

 Characteristics
of
Polymer Composites
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P.E. 406 Polymer Composites

 Advantages of Composites
 Provide capabilities for part integration
 Provide in-service monitoring or online
process monitoring
 They have a high specific stiffness (stiffness-
to-density ratio). Composites offer the
stiffness of steel at one fifth the weight and
equal the stiffness of aluminum at one half
the weight.

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P.E. 406 Polymer Composites

 Advantages of Composites
 The specific strength (strength-to-density ratio) of
a composite material is very high. Due to this,
airplanes and automobiles move faster and with
better fuel efficiency.
 The fatigue strength (endurance limit) is much
higher for composite materials. Steel and
aluminum alloys exhibit good fatigue strength
up to about 50% of their static strength.
Unidirectional carbon/epoxy composites have
good fatigue strength up to almost 90% of their
static strength.
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P.E. 406 Polymer Composites

 Advantages of Composites
 They offer high corrosion resistance.
 Composite materials offer increased amounts of
design flexibility. For example, the coefficient of
thermal expansion (CTE) of composite structures
can be made zero by selecting suitable
materials and lay-up sequence. Because the CTE
for composites is much lower than for metals,
composite structures provide good dimensional
stability.
 Net-shape or near-net-shape parts & complex
shapes can be produced
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P.E. 406 Polymer Composites

 Advantages of Composites
 Composites offer good impact properties
 Noise, vibration, and harshness (NVH)
characteristics are better than metals.
 Tailoring material properties to meet performance
specifications can be achieved thus avoiding
the over-design of products.
 The cost of tooling required for composites
processing is much lower

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P.E. 406 Polymer Composites

 Drawbacks of Composites
 The materials cost for composite materials is
very high compared to that of steel and
aluminum. It is almost 5 to 20 times more
than aluminum and steel on a weight basis.
 The lack of high-volume production methods
limits the widespread use of composite
materials.
 Lack of a database & design literature

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P.E. 406 Polymer Composites

 Drawbacks of Composites
 The temperature resistance of composite parts
depends on the temperature resistance of the
matrix materials. Because a large proportion of
composites uses polymer-based matrices,
temperature resistance is limited by the plastics’
properties.
 Composites absorb moisture, which affects the
properties and dimensional stability of the
composites.

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P.E. 406 Polymer Composites

 Summary - Advantages/Disadvantages

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P.E. 406 Polymer Composites

 Applications
of
Polymer Composites
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P.E. 406 Polymer Composites

 Composites Markets
 The products fabricated by composites are
stronger and lighter.
 Broadly speaking, the composites market can
be divided into the following industry
categories: aerospace, automotive,
construction, marine, corrosion resistant
equipment, consumer products,
appliance/business equipment, and others.

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P.E. 406 Polymer Composites

 COMPOSITES MARKETS

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P.E. 406 Polymer Composites

 The Aerospace Industry
 Among the first industry to realize the
benefits of composites
 Airplanes, rockets, and missiles all fly higher,
faster, and farther with the help of
composites
 The aerospace industry primarily uses carbon
fiber composites because of their high-
performance characteristics.

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P.E. 406 Polymer Composites

 The Aerospace Industry
 The hand lay-up technique is a common manufacturing
method for the fabrication of aerospace parts; RTM
and filament winding are also being used.
 Military aircrafts, such as the F-11, F-14, F-15, and F-
16, use composite materials to lower the weight of
the structure.
 Typical mass reductions achieved for the above
components are in the range of 20 to 35%. The mass
saving in fighter planes increases the payload
capacity as well as the missile range.

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P.E. 406 Polymer Composites

 Composite Components in
Aircraft Applications

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P.E. 406 Polymer Composites

 COMPOSITE COMPONENTS IN 
AIRCRAFT APPLICATIONS

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P.E. 406 Polymer Composites

 COMPOSITE COMPONENTS IN 
AIRCRAFT APPLICATIONS

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P.E. 406 Polymer Composites

 COMPOSITE COMPONENTS IN
AIRCRAFT APPLICATIONS

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P.E. 406 Polymer Composites

 COMPOSITE COMPONENTS IN 
AIRCRAFT APPLICATIONS

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P.E. 406 Polymer Composites

 The Aerospace Industry
 The major reasons for the use of composite
materials in spacecraft applications include
weight savings as well as dimensional stability.
 In low Earth orbit (LEO), where temperature
variation is from –100 to +100°C, it is important
to maintain dimensional stability in support
structures.
 Carbon epoxy composite laminates can be
designed to give a zero coefficient of thermal
expansion.
 Passenger aircrafts such as the Boeing 747 and
767 use composite parts to lower the weight, 78
increase the payload, and increase the fuel
P.E. 406 efficiency. Polymer Composites
 The Automotive Industry
 Composites are the “material of choice” in
some applications of the automotive
industry by delivering high-quality surface
finish, styling details, and processing
options.
 Manufacturers are able to meet automotive
requirements of cost, appearance, and
performance utilizing composites.

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P.E. 406 Polymer Composites

 The Automotive Industry
 Today, composite body panels have a successful
track record in all categories — from exotic
sports cars to passenger cars to small, medium,
and heavy truck applications.
 In 2000, the automotive industry used 318 million
pounds of composites.
 Because the automotive market is very cost-
sensitive, carbon fiber composites are not yet
accepted due to their higher material costs.
Automotive composites utilize glass fibers as
main reinforcements.
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P.E. 406 Polymer Composites

 Average Use of Composites in
Automobiles

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P.E. 406 Polymer Composites

 The Sporting Goods Industry
 Sports and recreation equipment suppliers are
becoming major users of composite materials.
 The growth in usage has been greatest in high-
performance sporting goods (golf shafts, tennis
rackets, snow skis, fishing rods, etc.)and racing
boats.
 These products are light in weight and provide
higher performance, which helps the user in
easy handling and increased comfort.

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P.E. 406 Polymer Composites

 Marine Applications
 The market for recreational transport include
bicycles, motorcycles, pleasure boats,
snowmobiles, and water scooters.
 Composite materials are used in a variety of
marine applications such as passenger ferries,
power boats, buoys, etc. because of their
corrosion resistance and light weight, which gets
translated into fuel efficiency, higher cruising
speed, and portability.

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P.E. 406 Polymer Composites

 Marine Applications
 The majority of components are made of glass-
reinforced plastics (GRP) with foam and
honeycomb as core materials.
 About 70% of all recreational boats are made of
composite materials
 Composites are also used in offshore pipelines for
oil and gas extractions.

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P.E. 406 Polymer Composites

 Composite Components in
Marine Applications

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P.E. 406 Polymer Composites

 Marine Applications
 The motivation for the use of GRP materials for Oil
and Gas applications includes reduced handling
and installation costs as well as better corrosion
resistance and mechanical performance.
 Another benefit comes from the use of adhesive
bonding, which minimizes the need for a hot
work permit if welding is employed.


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P.E. 406 Polymer Composites

 Consumer Goods
 Composite materials are used for a wide
variety of consumer good applications,
such as sewing machines, doors, bathtubs,
tables, chairs, computers, printers, etc.
 The majority of these components are short
fiber composites made by molding
technology such as compression molding,
injection molding, and RTM.

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P.E. 406 Polymer Composites

 Construction and Civil Structures
 The construction and civil structure industries
are the second major users of composite
materials.
 The driving force for the use of glass- and
carbon-reinforced plastics for bridge
applications is reduced installation,
handling, repair, and life-cycle costs as well
as improved corrosion and durability.

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P.E. 406 Polymer Composites

 Construction and Civil Structures
 It also saves a significant amount of time for
repair and installation and thus minimizes the
blockage of traffic.
 Composite usage in earthquake and seismic
retrofit activities is also booming. The columns
wrapped by glass/epoxy, carbon/epoxy, and
aramid/epoxy show good potential for these
applications.


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P.E. 406 Polymer Composites

 CONSTRUCTION AND CIVIL 
STRUCTURES

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P.E. 406 Polymer Composites

 Industrial Applications
 The use of composite materials in various
industrial applications is growing.
 Composites are being used in making industrial
rollers and shafts for the printing industry and
industrial drive shafts for cooling-tower
applications.


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P.E. 406 Polymer Composites

 Industrial Applications
 Filament winding shows good potential for
the above applications. Injection molded,
short fiber composites are used in
bushings, pump and roller bearings, and
pistons.
 Composites are also used for making robot
arms and provide improved stiffness,
damping, and response time.


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P.E. 406 Polymer Composites

 Barriers in Composite Markets
 The primary barrier to the use of composite
materials is their high initial costs in some
cases, as compared to traditional materials.
 Regardless of how effective the material will
be over its life cycle, industry considers
high upfront costs, particularly when the
life-cycle cost is relatively uncertain. This
cost barrier inhibits research into new
materials.
 In general, the cost of processing composites
is high, especially in the hand lay-up
process. Here, raw material costs represent 93
a small fraction of the total cost of a
P.E. 406 finished product. Polymer Composites
 Barriers in Composite Markets
 There is already evidence of work moving to Asia,
Mexico, and Korea for the cases where labor
costs are a significant portion of the total
product costs.
 The recycling of composite materials presents a
problem when penetrating a high-volume
market such as the automotive industry, where
volume production is in the millions of parts per
year.
 With the new government regulations and
environmental awareness, the use of composites
has become a concern and poses a big 94
challenge for recycling.
P.E. 406 Polymer Composites
 Reference
 Chapter # 1
Handbook of polymer
 composites for engineers
 by Leonard Hollaway
 Chapter # 2
 Composites Manufacturing
 by Sanjay K. Mazumdar


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P.E. 406 Polymer Composites