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Chapter 16 - 1
Chapter 16 - 2
Composite
Combination of two or more individual materials Design goal: obtain a more desirable combination of properties (principle of combined action) e.g., low density and high strength
Chapter 16 - 4
Terminology/Classification
Composite:
-- Multiphase material that is artificially made.
Phase types:
-- Matrix - is continuous -- Dispersed - is discontinuous and surrounded by matrix
Chapter 16 - 5
Chapter 16 - 6
Terminology/Classification
Matrix phase:
-- Purposes are to:
- transfer stress to dispersed phase - protect dispersed phase from environment
woven fibers
-- Types:
metal
ceramic
polymer
Dispersed phase:
-- Purpose:
MMC: increase sy, TS, creep resist. CMC: increase KIc PMC: increase E, sy, TS, creep resist.
Classification of Composites
Chapter 16 - 8
The degree of reinforcement or improvement of mechanical behavior depends on strong bonding at the matrixparticle interface. The volume fraction of the two phases influences the behavior; mechanical properties are enhanced with increasing particulate content. Examples: cermets, concrete
Chapter 16 - 10
Cermets
Large-particle composites are utilized with all three material types (metals, polymers, and ceramics). The cermets are examples of ceramicmetal composites. The most common cermet is the cemented carbide, which is composed of extremely hard particles of a refractory carbide ceramic such as tungsten carbide (WC) or titanium carbide (TiC), embedded in a matrix of a metal such as cobalt or nickel. These composites are utilized extensively as cutting tools for hardened steels. The hard carbide particles provide the cutting surface but, being extremely brittle, are not themselves capable of withstanding the cutting stresses. Toughness is enhanced by their inclusion in the ductile metal matrix, which isolates the carbide particles from one another and prevents particle-to-particle crack propagation. Both matrix and particulate phases are quite refractory, to withstand the high temperatures generated by the cutting action on materials that are extremely hard. No single material could possibly provide the combination of properties possessed by a cermet. Relatively large volume fractions of the particulate phase may be utilized, often exceeding 90 vol%; thus the abrasive action of the composite is Chapter 16 - 11 maximized.
Adapted from Fig. 10.19, Callister & Rethwisch 8e. (Fig. 10.19 is copyright United States Steel Corporation, 1971.)
Adapted from Fig. 16.4, Callister & Rethwisch 8e. (Fig. 16.4 is courtesy Carboloy Systems, Department, General Electric Company.)
(compliant) 0.75 mm
Adapted from Fig. 16.5, Callister & Rethwisch 8e. (Fig. 16.5 is courtesy Goodyear Tire and Rubber Company.)
Chapter 16 - 12
2. Dispersion strengthened composites For dispersion-strengthened composites, particles are normally much smaller, with diameters between 10 and 100 nm. Particlematrix interactions that lead to strengthening occur on the atomic or molecular level. The mechanism of strengthening is similar to that for precipitation hardening. Whereas the matrix bears the major portion of an applied load, the small dispersed particles hinder or impede the motion of dislocations. Thus, plastic deformation is restricted such that yield and tensile strengths, as well as hardness, improve. The high-temperature strength of nickel alloys may be enhanced significantly by the addition of about 3 vol% of thoria (ThO2) as finely dispersed particles; this material is known as thoria-dispersed (or TD) nickel. The same effect is produced in the aluminumaluminum oxide system. A very thin and adherent alumina coating is caused to form on the surface of extremely small (0.1 to 0.2 m thick) flakes of aluminum, which are dispersed within an aluminum metal matrix; this material is termed sintered aluminum powder (SAP).
Chapter 16 - 13
Prestressed concrete
- Rebar/remesh placed under tension during setting of concrete - Release of tension after setting places concrete in a state of compression - To fracture concrete, applied tensile stress must exceed this compressive stress
(Cu)
(W)
-- Electrical conductivity, se: Replace Es in equations with ses. -- Thermal conductivity, k: Replace Es in equations with ks.
Chapter 16 - 15
Fibers very strong in tension Provide significant strength improvement to the composite Ex: fiber-glass - continuous glass filaments in a polymer matrix
Glass fibers
strength and stiffness
Polymer matrix
holds fibers in place protects fiber surfaces transfers load to fibers
Chapter 16 - 16
Fiber Types
Whiskers - thin single crystals - large length to diameter ratios E.g graphite, silicon nitride, silicon carbide high crystal perfection extremely strong, strongest known very expensive and difficult to disperse Fibers polycrystalline or amorphous generally polymers or ceramics Ex: alumina, aramid, E-glass, boron, UHMWPE Wires metals steel, molybdenum, tungsten
Chapter 16 - 17
Longitudinal direction
Fiber Alignment
Adapted from Fig. 16.8, Callister & Rethwisch 8e.
Transverse direction
aligned continuous
Structural
2 mm
Chapter 16 - 19
Structural
C fibers: very stiff very strong
(a)
Other possibilities:
-- Discontinuous, random 3D -- Discontinuous, aligned
Adapted from F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig. 4.24(a), p. 151; (b) Fig. 4.24(b) p. 151. (Courtesy I.J. Davies) Reproduced with permission of CRC Press, Boca Raton, FL.
Chapter 16 - 20
fiber diameter
shear strength of fiber-matrix interface
Ex: For fiberglass, common fiber length > 15 mm needed For longer fibers, stress transference from matrix is more efficient
Short, thick fibers:
sd fiber length f 2 tc
Classification: Structural
Particle-reinforced
Fiber-reinforced Structural
Laminates -- stacked and bonded fiber-reinforced sheets - stacking sequence: e.g., 0/90 - benefit: balanced in-plane stiffness
Adapted from Fig. 16.16, Callister & Rethwisch 8e.
Sandwich panels
-- honeycomb core between two facing sheets - benefits: low density, large bending stiffness face sheet adhesive layer honeycomb
Adapted from Fig. 16.18, Callister & Rethwisch 8e. (Fig. 16.18 is from Engineered Materials Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)
Chapter 16 - 22
Composite Benefits
CMCs: Increased toughness
Force
particle-reinf
E(GPa)
10
fiber-reinf un-reinf
Bend displacement
10 -4
Density, r [mg/m3]
6061 Al
Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp. 139-146, 1984. Used with permission.
MMCs:
ess (s-1)
10 -6
10 -8
10 -10 20 30 50
s(MPa)
100 200
Chapter 16 - 23
Summary
Composites types are designated by:
-- the matrix material (CMC, MMC, PMC) -- the reinforcement (particles, fibers, structural)
-- MMC: enhanced E, s, creep performance -- CMC: enhanced KIc -- PMC: enhanced E/r, sy, TS/r -- Types: large-particle and dispersion-strengthened -- Properties are isotropic
Particulate-reinforced:
Fiber-reinforced:
-- Types: continuous (aligned) discontinuous (aligned or random) -- Properties can be isotropic or anisotropic
Structural:
-- Laminates and sandwich panels
Chapter 16 - 24