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Composite materials
Introduction
Definition: any combination of two or more different materials at the macroscopic level. OR Two inherently different materials that when combined together produce a material with properties that exceed the constituent materials.
Advantages
High strength and stiffness Low weight ratio Material can be designed in addition to the structure
Applications
Straw in clay construction by Egyptians Aerospace industry Sporting goods Automotive Construction
Types of Composites
Matrix phase/Reinforc ement Phase Metal Metal Ceramic
Polymer
Powder metallurgy parts combining immiscible metals Cermets, TiC, TiCN Cemented carbides used in tools Fiber-reinforced metals
Brake pads
Ceramic
Fiberglass
Kevlar fibers in an epoxy matrix Rubber with carbon (tires) Boron, Carbon reinforced plastics
MMCs
Metal Matrix Composites
CMCs
Ceramic Matrix Comps.
PMCs
Polymer Matrix Comps
D. Laminar Composites - 4
A lamina (laminae) is any arrangement of unidirectional or woven fibers in a matrix. Usually this arrangement is flat, although it may be curved, as in a shell. A laminate is a stack of lamina arranged with their main reinforcement in at least two different directions.
E. Filled Composites
There are two types of filled composites. In one, filler materials are added to a normal composite result in strengthening the composite and reducing weight. The second type of filled composite consists of a skeletal 3-D matrix holding a second material. The most widely used composites of this kind are sandwich structures and honeycombs.
cross-section can be circular, square or hexagonal Diameters --> 0.0001 - 0.005 Lengths --> L/D ratio
100 -- for chopped fiber much longer for continuous fiber
Particulate
small particles that impede dislocation movement (in metal composites) and strengthens the matrix For sizes > 1 Qm, strength of particle is involves in load sharing with matrix flat platelet form
Flakes
Fiber Reinforcement
The typical composite consists of a matrix holding reinforcing materials. The reinforcing materials, the most important is the fibers, supply the basic strength of the composite. However, reinforcing materials can contribute much more than strength. They can conduct heat or resist chemical corrosion. They can resist or conduct electricity. They may be chosen for their stiffness (modulus of elasticity) or for many other properties.
Types of Fibers
The fibers are divided into two main groups: Glass fibers: There are many different kinds of glass, ranging from ordinary bottle glass to high purity quartz glass. All of these glasses can be made into fibers. Each offers its own set of properties. Advanced fibers: These materials offer high strength and high stiffness at low weight. Boron, silicon, carbide and graphite fibers are in this category. So are the aramids, a group of plastic fibers of the polyamide (nylon) family.
Fibers - Glass
Fiberglass properties vary somewhat according to the type of glass used. However, glass in general has several well known properties that contribute to its great usefulness as a reinforcing agent:
Tensile strength Chemical resistance Moisture resistance Thermal properties Electrical properties
A C E S
Fibers - Glass
Most widely used fiber Uses: piping, tanks, boats, sporting goods Advantages
Low cost Corrosion resistance Low cost relative to other composites: Relatively low strength High elongation Moderate strength and weight E-Glass - electrical, cheaper S-Glass - high strength
Disadvantages
Types:
high performance replacement for glass fiber Armor, protective clothing, industrial, sporting goods
higher strength and lighter than glass More ductile than carbon
Examples
Advantages:
Fibers - Carbon
2nd most widely used fiber Examples
aerospace, sporting goods high stiffness and strength Low density Intermediate cost Properties:
Advantages
Standard modulus: 207-240 Gpa Intermediate modulus: 240-340 GPa High modulus: 340-960 GPa Diameter: 5-8 microns, smaller than human hair
vary in strength with processing Trade-off between strength and modulus PAN (Polyacrylonitrile)
fiber precursor heated and stretched to align structure
Intermediate modulus
High modulus
made from petroleum pitch precursor at lower cost much lower strength
Fibers - Others
Boron
High stiffness, very high cost Large diameter - 200 microns Good compressive strength Textile industry High strength Extremely light weight Low range of temperature usage
Very high temperature applications (e.g. engine components) Silicon carbide fiber - in whisker form. Ceramic matrix so temperature resistance is not compromised Infrequent use
Steel: density (Fe) = 7.87 g/cc; TS=0.380 GPa; Modulus=207 GPa Al: density=2.71 g/cc; TS=0.035 GPa; Modulus=69 GPa
Fiber Strength
Matrix Materials
Functions of the matrix
Transmit force between fibers arrest cracks from spreading between fibers
do not carry most of the load
Demands on matrix
Matrices - Polymeric
Thermosets
Most common, lower cost, solvent resistance Superior performance, relatively costly
Epoxy resins
Matrices - Thermosets
Polyester Polyesters have good mechanical properties, electrical properties and chemical resistance. Polyesters are amenable to multiple fabrication techniques and are low cost. Vinyl Esters Vinyl Esters are similar to polyester in performance. Vinyl esters have increased resistance to corrosive environments as well as a high degree of moisture resistance.
Matrices - Thermosets
Epoxy Epoxies have improved strength and stiffness properties over polyesters. Epoxies offer excellent corrosion resistance and resistance to solvents and alkalis. Cure cycles are usually longer than polyesters, however no by-products are produced. Flexibility and improved performance is also achieved by the utilization of additives and fillers.
Matrices - Thermoplastics
Formed by heating to elevated temperature at which softening occurs
Reversible reaction Can be reformed and/or repaired - not common Limited in temperature range to 150C Polypropylene
with nylon or glass can be injected-- inexpensive
Examples
Soften layers of combined fiber and resin and place in a mold -- higher costs
Matrices - Others
Metal Matrix Composites - higher temperature
Fiber is used to add toughness, not necessarily higher in strength and stiffness
Important Note
Composite properties are less than that of the fiber because of dilution by the matrix and the need to orient fibers in different directions.
The processing of fiber reinforced laminates can be divided into two main steps: Lay up Curing Curing is the drying and hardening (or polymerization) of the resin matrix of a finished composite. This may be done unaided or by applying heat and/or pressure. Lay up basically is the process of arranging fiber reinforced layers (laminae) in a laminate and shaping the laminate to make the part desired. (The term lay up is also used to refer to the laminate itself before curing.) Unless prepregs are used, lay up includes the actual creation of laminae by applying resins to fiber reinforcements.
A. Winding Operation
The most important operation in this category is filament winding. Fibers are passed through liquid resin, and then wound onto a mandrel. After lay up is completed, the composite is cured on the mandrel. The mandrel is then removed by melting, dissolving, breaking out or some other method.
B. Molding Operations
Molding operations are used in making a large number of common composite products. There are two types of processes:
A. Open mold
(1) (2) (3) (4) (5) (6) (7) (8) Hand lay up Spray up Vacuum bag molding Pressure bag molding Thermal expansion molding Autoclave molding Centrifugal casting Continuous pultrusion and pulforming.
1. Hand Lay-up
Hand lay up, or contact molding, is the oldest and simplest way of making fiberglass resin composites. Applications are standard wind turbine blades, boats, etc.)
2. Spray-up
In Spray up process, chopped fibers and resins are sprayed simultaneously into or onto the mold. Applications are lightly loaded structural panels, e.g. caravan bodies, truck fairings, bathtubes, small boats, etc.
3. Vacuum-Bag Molding
The vacuum bag process was developed for making a variety of components, including relatively large parts with complex shapes. Applications are large cruising boats, racecar components, etc.
4. Pressure-Bag Molding
Pressure bag process is virtually a mirror image of vacuum bag molding. Applications are sonar domes, antenna housings, aircraft fairings, etc.
6. Autoclave Molding
Autoclave molding is similar to both vacuum bag and pressure bag molding. Applications are lighter, faster and more agile fighter aircraft, motor sport vehicles.
7. Centrifugal Casting
Centrifugal Casting is used to form round objects such as pipes.
Pulforming is similar to pultrusion in many ways. However, pultrusion is capable only of making straight products that have the same volume all along their lengths. Pulformed products, on the other hand, can be either straight or curved, with changing shapes and volumes. A typical pulformed product is a curved reinforced plastic car spring. (shown in figure.)
B. Closed mold
(1) Matched die molding: As the name suggests, a matched die mold consists of closely matched male and female dies (shown in figure). Applications are spacecraft parts, toys, etc. (2) Injection molding: The injection process begins with a thermosetting (or sometimes thermoplastic) material outside the mold. The plastic may contain reinforcements or not. It is first softened by heating and/or mechanical working with an extrusion type screw. It is then forced, under high pressure from a ram or screw, into the cool mold. Applications are auto parts, vanes, engine cowling defrosters and aircraft radomes.
low manufacturing costs if high throughput e.g., Glass fiber pipe, sailboard masts
Prepregs
Prepreg and prepreg layup
Curing conditions
Typical temperature and pressure in autoclave is 120-200C, 100 psi
Manufacturing - Layups
compression molding
vacuum bagging
Material Forms
Textile forms
Braiding or weaving
Tubular braided form
Fabric Structures
Woven: Knit: Braided: Series of Interlaced yarns at 90 to each other Series of Interlooped Yarns Series of Intertwined, Spiral Yarns
Woven Fabrics
Basic woven fabrics consists of two systems of yarns interlaced at right angles to create a single layer with isotropic or biaxial properties.
Physical Properties
Construction (ends & picks) Weight Thickness Weave Type
Braiding
A braid consists of two sets of yarns, which are helically intertwined. The resulting structure is oriented to the longitudinal axis of the braid. This structure is imparted with a high level of conformability, relative low cost and ease of manufacture.
Braid Structure
Types of Braids
Triaxial Yarns
A system of longitudinal yarns can be introduced which are held in place by the braiding yarns These yarns will add dimensional stability, improve tensile properties, stiffness and compressive strength. Yarns can also be added to the core of the braid to form a solid braid.
Pultrusion
Manufacturing
Tube rolling - tubular products
Examples
fishing rods golf clubs oars