Chapter 12 Composite Engineering Material

Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display
CHAPTER
12
Composite
Materials
1
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display
Introduction
Every material is composite at one or the other level.
A composite material is a material system, a mixture or
combination of two or more micro (10-4 ~ 10-2 cm) or
macroconstituents (> 10-2cm) that differ in form and
composition and do not form a solution.
Properties of composite materials can be superior to its
individual components. Unusual combinations of stiffness,
strength, weight, high-temperature performance, corrosion
resistance, hardness, conductivity or etc.
Examples: Fiber reinforced plastics, concrete, asphalt,

wood etc.
Foundations of Materials Science and Engineering, 5th Edn. Smith and Hashemi
Classification of composite
Adapted from, Callister 6e
eg. Concrete
eg. Automobile
tire
Fibers for Reinforced-Plastic Composite Materials

Synthetic Fibers:
Glass Fibers
Carbon Fibers
Aramid Fibers
Matrix Materials
Unsaturated polyesters
Epoxy resins
6
Glass Fibers for Reinforced Plastic Composite Materials
Glass fiber reinforced plastic composite materials have

high strength-weight ratio, good dimensional stability,
good temperature and corrosion resistance and low cost.
E (electrical) Glass : 52-56% SiO2, + 12-16%
Al2O3, 16-25% CaO + 8-13% B2O3
Tensile strength = 3.44 GPa, E = 72.3 GPa
S (high-strength) Glass : Used for military and

aerospace application.
65% SiO2 + 25% Al2O3 + 10% MgO
Tensile strength = 4.48 GPa, E = 85.4 GPa
Production of Glass Fibers

Produced by drawing monofilaments from a furnace and
gathering them to form a strand.
Strands are held together with resinous binder.
Properties: Density
and strength are lower
than carbon and aramid
fibers.
Higher elongation.
Low cost and hence
commonly used.
8
Fiberglass chopped strand
Fiberglass mesh
Fiberglass fabric
Fiberglass Mat
Fiberglass woven
9
Carbon Fibers for Reinforced Plastics
Light weight, very high strength and high stiffness.

7-10 micrometer in diameter.
Produced from polyacrylonitrile (PAN) and pitch.
Steps:
Stabilization: PAN fibers are stretched and oxidised in air at
about 2000C.
Carbonization: Stabilized carbon fibers are heated in inert
atmosphere at 1000-15000C which results in elimination of
O,H and N resulting in increase of strength.
Graphitization: Carried out at 18000C and increases modulus
of elasticity at the expense of strength
10
Tensile strength = 3.1-4.45 GPa, E = 193-241 GPa,

density = 1-7-2.1 g/cc.
Carbon fibers (cont)
11
Aramid Fibers for Reinforcing Plastic Resins
Aramid = aromatic polyamide fibers.

Trade name is Kevlar
Kevlar 29:- Low density, high strength, and used for ropes and
cables.
Kevlar 49:- Low density, high strength and modulus and used for
aerospace and auto applications.
Hydrogen bonds bond fiber together.
Used where resistance to fatigue, high strength and light

weight is important.
12
Aramid fibers
Bullet proof jacket
Bullet proof
helmet
13
Comparison of Mechanical Properties
Carbon fibers provide best combination of properties.

Due to favorable properties, carbon and aramid fiber
reinforced composites have replaced steel and aluminum in
aerospace applications.
14
Matrix Materials
Polyester and epoxy resins are the two important matrix

materials.
Polyester resins: Cheaper but than epoxy resins.
Applications: Boat hulls, auto and aircraft applications.
Epoxy resins: Good strength, low shrinkage.
Commonly used matrix materials for carbon and
aramid-fiber composite.
15
The Matrix Phase

Matrix phase serves several functions:
It binds the fibers together and acts as a medium by
which an externally applied stress is transmitted and
distributed to the fibers
To protect the individual fibers from surface damage as
a result of mechanical abrasion or chemical reactions
with the environment.
Separates the fiber and serves as a barrier to crack
propagation
It is essentials that adhesive bonding forces between fiber
and matrix to be high to minimize fiber pull out
Ultimate strength of composite depends on the magnitude
of this bond
Polymer Matrix Composite (PMC)
Consists of polymer resin (matrix) with fiber as

the reinforcement medium
PMC
Glass Fiber
Reinforcing
Polymer
Carbon Fiber
Reinforcing
Polymer
(GFRP)
(CFRP)
Aramid fiber
reinforcing
polymer
Other
reinforcement
Carbon Fiber Reinforced Polymer (CFRP)

Carbon is a high performance fiber material that is most commonly used
reinforcement in advanced polymer matrix composite
Carbon fiber contributes to rigidity and strength while epoxy matrix contributes
to impact strength.
Polyimides, polyphenylene sulfides are also used.
Exceptional fatigue properties.
Carbon fiber epoxy material is laminated to meet strength requirements.
Advantages
Carbon fibers have the highest specific modulus and specific strength of
reinforcing fiber materials
Able to retain high tensile modulus and high strength at elevated
temperature (but not in high-temperature oxidation condition)
Resistance to high temperatures and corrosive chemicals
Diversity of physical and mechanical characteristic of the fibers
Manufacturing process relatively inexpensive and cost effective
Application : Sports and recreational equipment (fishing rod, golf clubs),
filament-wound rocket motor cases, pressure vessel and aircraft structural
components
Glass Fiber Reinforcing Polymer (GFRP)
Fiberglass is a composite consisting of glass fibers (continuous or discontinuous),

contained within a polymer matrix
Fiber diameter range: 3-20 m
Higher the wt% of glass, stronger the reinforced plastic is.
Nonparallel alignment of glass fibers reduces strength.
Advantages of glass as fiber reinforcement because:
Easily drawn into high-strength fibers from molten state
Readily available and maybe fabricated into glass-reinforced plastic
Relatively strong and produces a composite having high specific strength
Chemical resistance; useful in corrosive environment
Disadvantages:
Not very stiff and do not display rigidity that is necessary for some application
(e.g: structural member for air plane and bridges)
Limited to service below 200C. at higher temperature it begin to
flow/deteriorate
Application: automotive and marine bodies, plastic pipes, storage containers and
industrial flooring
Properties of Fiber Reinforced Plastics
20
Fatigue Characteristics of Fiber Reinforced Plastics
Lamination
21
Equation for Elastic Modulus of Lamellar Composite
Isostrain condition: Stress on composite causes uniform

strain on all composite layers.
Pc = Pf + Pm
Pc = Load on composite
Pf = Load on fibers
Pm = load on matrix
= P/A
cAc = fAf + mAm
Since length of layers are equal,

cVc = fVf + mVm Where Vc, Vf and Vm are volume
fractions (Vc =1)
f V f mVm
c
Since strains c = f = m,
Ec = EfVf + EmVm
Rule of mixture of binary composites

22
Loads on Fiber and Matrix Regions
Since = E and f = m
f Af
E f f Af
E f Af
EfVf
Pm m Am E m m Am E m Am E mVm
Pf
Pc = Pf + Pm
From above two equations, load on each of fiber and

matrix regions can be determined if values of Ef, Em, Vf, Vm
and Pc are known.
23
Isostress Condition
Stress on the composite structure produces an equal stress

condition on all the layers.
c = f + m
c = f + m
Assuming no change in area

and assuming unit length of the composite
c = fVf + mVm
, f
, m
But c
Ec
Therefore
Ec
V f
Ef
Ef
Em
Vm
Em
24
Elastic Modulus for Isostress Condition
We know that
Ec
V f
Ef
Vm
Em
Dividing by
V f Vm
1
Ec E f Em
V f E m Vm E f
1
Ec E f E m Em E f
Ec
25
E f Em
V f E m Vm E f
Higher modulus values are

obtained with isostrain
loading for equal volume of
fibers
Example Problem
Open Mold Process for Fiber Reinforced Plastics
Hand lay-up process:

Gel coat is applied to open mold.
Fiberglass reinforcement is
placed in the mold.
Base resin mixed
with catalysts is
applied by pouring
brushing or spraying.
Spray-up process: Continuous
strand roving is fed by chopper
and spray gun and chopped
roving and catalyst resin is
deposited in the mold.
27
Spray up is a traditional openmold process in which chopped

fiber and thermoset resin is
sprayed on to a mold,
consolidated and then cured.
This process dominated
composites for many years, but
is gradually being replaced by
closed-mold processes like
Resin transfer molding (RTM.)
28
Vacuum Bag-Autoclave and Filament Winding
Vacuum bag-autoclave process:

Long thin sheet or prepeg carbon-fiber epoxy
material is laid on the table.
The sheet is cut and laminate is constructed.
Laminate is put in vacuum bag to remove entrapped
air and cured in autoclave.
Filament winding:
Fiber reinforcement is fed
through resin bath and
wound around suitable
mandrel.
Mandrel is cured and mold part is stripped from
mandrel.
29
Closed Mold Process

Compression and injection molding:
Same as in polymers except that the fiber reinforcement
is mixed with resin.
Sheet molding compound process:
Highly automated continuous molding process.
Continuous strand fiberglass
roving is chopped and deposited
on a layer of resin-filler paste.
Another layer of paste is
deposited on first layer.
Sandwich is compacted
and rolled into rolls.
30
Sheet Molding (Cont..)
The rolled up sheet is stored in a maturation room for 1-4

days.
The sheets are cut into proper size and pressed in hot mold
(1490C) to form final product.
Efficient, quick, good quality and uniformity.
Continuous protrusion: Continuous strand fibers are
impregnated in resin bath, fed into heated die and drawn.
Used to produce
beams, channels,
and pipes.
31
Concrete
Flexible, economical, fire resistant, durable, fabricated on

site.
Low tensile strength, less ductile and shrinkable.
Concrete is a ceramic composite composed of coarse
granular material embedded in hard matrix of cement
paste.
Concrete = 7-15% Portland cement, 14-21% water, 8% air, 24-30% fine aggregate and 31-51% coarse
aggregate.
32
Compressive Strength
Compressive strength is higher than tensile strength and

depends up on settled time.
High water content reduces compressive strength.
Air entrainment improves workability and hence water
content can be reduced.
Air
Bubbles
33
Asphalt and Asphalt Mixes
Asphalt is a bitumen
Hydrocarbon.
80-85% C, 9-10% H, 2-8% O, 0.5-7% sulfur and traces of
impurities.
Asphalt + Aggregate
Asphalt mixture
used
primarily for paving roads.
Obtained primarily from petroleum refining but also from
rocks and surface deposits.
Angular aggregate bonds better with asphalt and produces
better skid resistance on pavements.
34
Sandwich Structure
Composite materials are also made by sandwiching a core

material between two thin outer layers.
Honeycomb sandwich: Fabricated by adhesively bonding
aluminum alloy face
sheets to aluminum alloy
honeycomb core sections.
Stiff, rigid strong and used
in aerospace applications.
Clad metal structure: Metal core and thin outer layer of
other metal are bonded by hot rolling.
Example: 10 cent and 25 cent coins have cladding of
Cu -25% Ni alloy over less expensive Cu core.
40
Metal Matrix Composites (MMCs)
Continuous fiber reinforced MMCs: Continuous fibers are

reinforced in metal matrix used in aerospace, auto
industry and sports equipments.
Example:- Aluminum alloy Boron fiber composite
Boron fiber is made by depositing boron vapor on tungsten
substrate.
Boron fibers are hotpressed between aluminum foils.
Tensile strength of Al6061 increases from 310 to 1417GPa and E
increases from 69 to 231 GPa
Tungsten filament
Boron
41
Figure 11.46
Discontinuous fiber and particulate reinforced MMCs
Particulate reinforced MMCs: Irregular shaped alumina

and silicon carbide particulate are used.
Particulate is mixed into molten aluminum and cast into
ingots or billets.
Tensile strength increased to 496 MPa
Al 6061 + 20% SiC
E increased to 103 GPa
Discontinuous fiber reinforced MMcs: Needle like SiC
whiskers (1-3 micron diameter, 20-200 micron in length)
are mixed with metal powder.
Mixture is consolidated by hot pressing
and then forged or extruded.
Tensile strength of Al 6061 increases to
480 MPa and E increases to 115 GPa
Figure 11.47a
42
Metal-Matrix Composite (MMC)

Matrix ductile metal
e.g.: superalloy, as well as aluminum, magnesium, titanium & copper
reinforcement:
May improve specific stiffness, specific strength, abrasion resistance, creep
resistance, thermal conductivity and dimensional stability
Form:
particulates,
continuous fiber e.g.: carbon, silicon carbide, boron, alumina and refractory
material
discontinuous fiber e.g.: silicon carbide and alumina
whiskers
Some matrix-reinforcement combinations are highly reactive at elevated temperature
May cause composite degradation due to high temperature processing or during
service at elevated temperature
Problem is resolved by:
Applying a protective surface coating to the reinforcement
Modifying the matrix alloy composition
Metal-Matrix Composite (MMC) (cont)
Advantages over PMC

1. Higher operating temperature
2. Nonflammability
3. Greater resistance to degradation in contact of organic fluids
Disadvantages
1. Expansive than PMC, thus limited usage
Application
1. Automotive: engine components
Aluminum alloy matrix with alumina and carbon fiber reinforcement
Light in weight and resist wear thermal distortion
2.
Aerospace structural applications

Aluminum alloy matrix with boron fiber reinforcement for space
shutter orbiter
Aluminum alloy matrix with continuous graphite fiber reinforcement
for Hubble Telescope
Ceramic-Matrix Composites (CMCs)
45
Continuous fiber reinforced CMCs:

SiC fibers are woven into mat and SiC is impregnated
into fibrous mat by chemical vapor deposition.
SiC fibers can be encapsulated by a glass ceramic.
Used in heat exchanger tube and thermal protection
system.
Discontinuous and particulate reinforced CMCs:
Fracture toughness is significantly increased.
Fabricated by common process such as hot isolatic
pressing.
Toughening Mechanisms in CMCs
46
Toughening is due to fibers interfering with crack

propagation.
Crack deflection: Up on encountering reinforcement,
crack is deflected making propagation more meandering.
Crack bridging: Fibers bridge the crack and help to keep
the cracks together.
Fiber pullout: Friction caused by pulling out the fiber
from matrix results in higher toughness.
Nanotechnology: Carbon nanotubes integrated with
alumina.
Fracture toughness increases by 5 times.
Conducts electricity.
Ceramic matrix composite

Ceramic fracture toughness value are low (1-5 MPam)
Development of ceramic-matrix composite
Shows improved high-temperature creep behavior
Resistance to thermal shock
Particles, fibers or whiskers of one ceramic materials have been
embedded into a ceramic matrix
increase the fracture toughness value (6-20 MPam) interaction
between advancing cracks and dispersed phase particles
Crack initiation normally occurs with the matrix phase
Crack propagation is hindered by the particles, fibers or whiskers
Ceramic matrix composite (cont)

Transformation toughening is a toughening technique employed to prevent
crack propagation
The stress field in front of a propagation crack causes these metastable
retained tetragonal particles to undergo transformation to the stable
monoclinic phase
Small particles of partially stabilized zirconia (PSZ) are dispersed
within the matrix material often Al2O3
CaO, MgO, and CeO are used as stabilizers
Partially stabilization allows retention of the metastable tetragonal phase
at ambient conditions rather than monoclinic phase
Accompanying this transformation is a slight particle volume increase,
the net result is that compressive stresses are established on the crack
surfaces near the crack tip
Example: SiC whiskers-reinforced alumina are being utilized as cutting
tool inserts for machining hard metal alloys (greater performance than
that cemented carbide)
Carbon-carbon Composites
Most advanced and promising engineering material
Both reinforcement and matrix are carbon
Relatively new and expensive and currently not being extensively
utilized
The properties :
high tensile moduli and tensile strength
Resistance to creep
Large fracture toughness
Low coefficient of thermal expansion and thermal conductivity
Example :
As friction materials in aircraft and high performance
automobiles
Hot pressing molds
Components of advanced turbine engine

Chapter 12 Composite Engineering Material

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Chapter 12 Composite Engineering Material

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Examples: Fiber reinforced plastics, concrete, asphalt,

Fibers for Reinforced-Plastic Composite Materials

Glass Fibers for Reinforced Plastic Composite Materials

Glass fiber reinforced plastic composite materials have

S (high-strength) Glass : Used for military and

Production of Glass Fibers

Fiberglass chopped strand

Carbon Fibers for Reinforced Plastics

Light weight, very high strength and high stiffness.

Tensile strength = 3.1-4.45 GPa, E = 193-241 GPa,

Carbon fibers (cont)

Aramid Fibers for Reinforcing Plastic Resins

Aramid = aromatic polyamide fibers.

Hydrogen bonds bond fiber together.

Used where resistance to fatigue, high strength and light

Bullet proof jacket

Comparison of Mechanical Properties

Carbon fibers provide best combination of properties.

Polyester and epoxy resins are the two important matrix

The Matrix Phase

Polymer Matrix Composite (PMC)

Consists of polymer resin (matrix) with fiber as

Carbon Fiber Reinforced Polymer (CFRP)

Glass Fiber Reinforcing Polymer (GFRP)

Fiberglass is a composite consisting of glass fibers (continuous or discontinuous),

Properties of Fiber Reinforced Plastics

Fatigue Characteristics of Fiber Reinforced Plastics

Equation for Elastic Modulus of Lamellar Composite

Isostrain condition: Stress on composite causes uniform

Since length of layers are equal,

Rule of mixture of binary composites

Loads on Fiber and Matrix Regions

From above two equations, load on each of fiber and

Stress on the composite structure produces an equal stress

Assuming no change in area

Elastic Modulus for Isostress Condition

Higher modulus values are

Open Mold Process for Fiber Reinforced Plastics

Hand lay-up process:

Spray up is a traditional openmold process in which chopped

Vacuum Bag-Autoclave and Filament Winding

Vacuum bag-autoclave process:

Closed Mold Process

Sheet Molding (Cont..)

The rolled up sheet is stored in a maturation room for 1-4

Flexible, economical, fire resistant, durable, fabricated on

Compressive strength is higher than tensile strength and

Asphalt and Asphalt Mixes

Composite materials are also made by sandwiching a core

Metal Matrix Composites (MMCs)

Continuous fiber reinforced MMCs: Continuous fibers are

Discontinuous fiber and particulate reinforced MMCs

Particulate reinforced MMCs: Irregular shaped alumina

Metal-Matrix Composite (MMC)

Metal-Matrix Composite (MMC) (cont)

Advantages over PMC

Aerospace structural applications

Ceramic-Matrix Composites (CMCs)

Continuous fiber reinforced CMCs:

Toughening Mechanisms in CMCs

Toughening is due to fibers interfering with crack