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MATERIALS
COMPOSITES
-Composite materials are engineered materials made
from two or more constituent materials that remain
separate and distinct while forming a single component
-Generally, one material forms a continuous matrix while
the other provides the reinforcement
- The two materials must be chemically inert with respect
to each other so no interaction occurs upon heating until
one of the components melts, an exception to this
condition is a small degree of interdiffusion at the
reinforcement-matrix interface to increase bonding
COMPOSITES
Composites can be classified by their
matrix material which include:
-Metal matrix composites (MMCs)
-Ceramic matrix composites (CMCs)
-Polymer matrix composites (PMCs) or
sometimes referred to as organic matrix
composites (OMCs)
COMPOSITES
COMPOSITES
COMPOSITES
CMC Ceramic Matrix Composites
-The matrix is relatively hard and brittle
-The reinforcement must have high tensile strength to
arrest crack growth.
Some commonly used fibers for metal matrix composites:
Special silicon carbide (SiC)
Alumina (Al2O3)
Mullite (Al2O3SiO2)
Composite Benefits
CMCs: Increased toughness
Force
103
particle-reinf
un-reinf
10 -4
6061 Al
ss (s-1)
10 -6
10 -8
10 -10
metal/
metal alloys
.1 G=3E/8 polymers
.01 K=E
.1 .3 1 3 10 30
Density, [mg/m3]
Bend displacement
Increased
creep
resistance
ceramics
E(GPa)
PMCs
102
10
fiber-reinf
MMCs:
PMCs: Increased E/
6061 Al
w/SiC
whiskers
20 30 50
(MPa)
100 200
Composite Survey
C o m p o s it e s
P a r t ic le - r e in fo r c e d
L a rg e p a r t ic le
D is p e r s io n s tre n g th e n e d
F ib e r - r e in fo r c e d
C o n t in u o u s
( a lig n e d )
S tru c tu ra l
D is c o n t in u o u s
(s h o rt)
A lig n e d
R a n d o m ly
o r ie n t e d
L a m in a t e s
S a n d w ic h
p a n e ls
Fiber-reinforced
(ductile)
60 m
- WC/Co
cemented
carbide
matrix:
cobalt
(ductile)
Vm :
5-12 vol%!
Structural
particles:
cementite
(Fe3 C)
(brittle)
particles:
WC
(brittle,
hard)
600 m
- Automobile matrix:
rubber
tires
particles:
C
(stiffer)
(compliant)
0.75 m
Fiber-reinforced
Structural
threaded
rod
Fiber-reinforced
Structural
(Cu)
lower limit:
1 Vm Vp
=
+
Ec Em Ep
20 40 60 80
10 0 vol% tungsten
(W)
Fiber-reinforced
Structural
f d
fiber length 15
c
fiber diameter
shear strength of
fiber-matrix interface
Ex: For fiberglass, a fiber length > 15 mm is needed since this length
provides a Continuous fiber based on usual glass fiber properties
(x)
*f d
lc
2 c
Fiber-reinforced
Structural
Fiber Materials
Whiskers - Thin single crystals - large length to diameter ratio
graphite, SiN, SiC
high crystal perfection extremely strong, strongest known
very expensive
Fibers
polycrystalline or amorphous
generally polymers or ceramics
Ex: Al2O3 , Aramid, E-glass, Boron, UHMWPE
Wires
Metal steel, Mo, W
Fiber Alignment
Adapted from Fig.
16.8, Callister 7e.
aligned
continuous
aligned
random
discontinuous
Longitudinal deformation
c = mVm + fVf
but
volume fraction
Ece = Em Vm + EfVf
Ff
EfVf
Fm E mVm
c = m = f
isostrain
longitudinal (extensional)
modulus
Remembering: E = /
f = fiber
m = matrix
1
Vm Vf
Ect E m Ef
c= mVm + fVf
transverse modulus
Remembering: E = /
and note, this model
corresponds to the lower
bound for particulate
composites
An Example:
UTS, SI
Modulus, SI
57.9 MPa
3.8 GPa
2.4 GPa
399.9 GPa
(241.5 GPa)
(9.34 GPa)
Composite Strength
Particle-reinforced
Fiber-reinforced
Structural
Ec = EmVm + KEfVf
efficiency factor:
-- aligned 1D: K = 1 (aligned )
-- aligned 1D: K = 0 (aligned )
-- random 2D: K = 3/8 (2D isotropy)
-- random 3D: K = 1/5 (3D isotropy)
-- TS in fiber direction:
(aligned 1D)
by eutectic solidification.
(a)
2 m
Structural
(b)
fracture
surface
From F.L. Matthews and R.L.
Rawlings, Composite Materials;
Engineering and Science, Reprint
ed., CRC Press, Boca Raton, FL,
2000. (a) Fig. 4.22, p. 145 (photo by
J. Davies); (b) Fig. 11.20, p. 349
(micrograph by H.S. Kim, P.S.
Rodgers, and R.D. Rawlings). Used
with permission of CRC
Press, Boca Raton, FL.
(b)
C fibers:
very stiff
very strong
C matrix:
less stiff
view onto plane less strong
Other variations:
-- Discontinuous, random 3D
-- Discontinuous, 1D
Structural
(a)
Ec = EmVm + KEfVf
efficiency factor:
-- random 2D: K = 3/8 (2D isotropy)
-- random 3D: K = 1/5 (3D isotropy)
fibers lie
in plane
Looking at strength:
l lC
cd
lC
'
Vf 1
m 1Vf
2
l
l lC
cd '
l C
V f m' 1 V f
d
Fiber-reinforced
Structural
Sandwich panels
-- low density, honeycomb core
-- benefit: light weight, large bending stiffness
face sheet
adhesive layer
honeycomb
Adapted from Fig. 16.18,
Callister 7e. (Fig. 16.18 is
from Engineered Materials
Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)