INTRODUCTION
ME 6209 / A. Haque
Basic Definition of Composite
Materials
A MATERIAL CONSISTING OF ANY COMBINATION OF FIBERS,
WHISKERS AND PARTICLES (Reinforcements) IN A COMMON MATRIX
Reinforcements (Fiber, Whisker, Particles)
Matrix
Metal Ceramic Polymer
Polymeric X X X
Ceramic X X X
Metal X X X
Composite Sandwich Structures
Classification of Composite
Materials
Composite Materials
Fiber-reinforced Particle-reinforced
composites composites
(fibrous composites) (particulate composites)
Single-layer composites Multilayered (angle-ply) Random Preferred
(including composites having composites Orientation Orientation
same orientation and properties
in each layer)
Laminates Hybrids
Continuous-fiber-reinforced Discontinuous-fiber-reinforced
composites composites
Unidirectional Bidirectional Random Preferred
reinforcement Reinforcement Orientation Orientation
(woven reinforcements)
Brief History of Composites
• Straw-reinforced mud bricks (Egypt, 800 B.C.)
• Glass fibers developed in 1940’s.
• Boron, graphite and aramid fibers introduced in late 1960’s.
• Considerable work on metal matrix composites in the late
1960’s- Numerous boron/aluminum components developed.
• Interest in MMC and CMC dropped by early 1970’s. But
recently, CMC is aggressively pursued for gas turbine engine
blades.
• Polymer matrix composites became dominant materials due
to
– Good structural properties
– Ease of Fabrication
– Lower cost than MMC and CMC
Why Composites?
• High specific strength (strength/density)
• High specific stiffness (stiffness/density)
• Low density
• Unique combination of properties
• Corrosion resistance
• Wear resistance
• Fatigue resistance
• Creep resistance
• Electrically and thermally non-conductive and conductive
• Design flexibility by
– Choosing fibers
– Varying resin formulation
– Wide range of processing and fabrication methods
Comparison of Strength and
Stiffness: Metal vs. Composites
Comparison of Stiffness and Toughness:
Fibers, Resin, Composites and Metals
Fatigue Properties (Tension-Tension):
Unidirectional Composites vs. Metals
Fatigue Properties: Metal vs.
Composites
Comparison of I-Beam Properties:
Metals vs. Composites
Design Curves for Al & Boron/Epoxy I-
Beams used in Commercial Aircrafts
See how height and weight of
the beam change for equivalent stiffness
kg and strength:
Constant parameters
in
Maximum Use Temperature vs.
Density: Composites and Metals
Design Flexibility Inherent in
Composite Constructions
• Modulus, strength, and
thickness can be varied through
design and material choices
Tensile Modulus of Graphite/Epoxy
Composites vs. Fiber Orientation
Application Trends of Metal,
Polymer, Composite, and Ceramic
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Applications of Polymer Matrix
Composites-Components
Aircrafts: Doors, wing boxes, frames, flaps
stiffners, floor beam, fuselage & wing skin, Ailerions, rudders
(Military & Commercial)
Space: Space shuttle, Nose cone, space station “Freedom”,
pressure vessel (kv-49/ep), mirrors/lens in space telescope.
Automotive: Body frame (E-glass/polyester),chasis components (leaf
spring-Eglass/ep), drive shafts, exterior, interior body
components.
Marine: Hulls & masts, submersibles, spars, decks, bulkheads, etc.
(glass/polyester, kevlar99/epoxy)
Sports Goods: Tennis, racquetball racquet, golf club shafts &
heads, bicycle frames, skies, canoes, helmets (vibration
damping), fishing rod, bicycle frames, hockey sticks (Table -
1.5/ P. K. Mallick)
Chemical: Pipes, tanks.
Construction: Structural & decorative panels, fuel tanks, bridge,
housing doors.
Electrical: Printed circuit board, computer housings.
Early Commercial Airpalne-Boeing-757-1983
(Composite < 20%, Aluminum : 60%, Others 20%)
Boeing 787-Dreamliner: Lunched 2009
Composite 50%
Aluminum 20 %
Titanium 15 %
Steel 5%
Other 5%
Cruising Speed : 647 mph
Range : 7,650-8200 miles
Engine: GE /Rolls-Royce
Production : 10 jets every
month by 2013
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Composite Structure : Airbus A350XWB
Composite in Military Aircrafts
McDonnell-Douglas F-15 Fighter F-18 Fighter
Composites in F-15
F-35 Military Aircraft: 35% composite parts
Stealth Fighter : Complete Composite
Body: Lockheed 117
Composite Military Helicopter
Composites Applications in the Sikorsky Aircraft UH-60A
Black Hawk Helicopter
Composites in Helicoptor
Airbus H160
First all composite Helicopter
Key Composite Parts in Automobile
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Composite Leaf Spring and Power
Transmission Shaft
<
Filament wound composite
power transmission shaft
(Ford)
>
Liteflex composite
leaf springs
(Delco, GM)
Automotive application: Mercedes
Benz hood of composites
Composite Race Car body
Composites in Electric Vehicles
Composite in Infrastructures
Bridge : Replace reinforced concrete and steel by FRP
- Corrosion problem is eliminated by FRP
Composites in Infrastructures
Composites in Sport Goods
• Tennis rackets
• Golf club shafts
• Fishing rod
• Bicycle frame
• Hockey sticks
• Canoe hulls
• Arrows
• Helmets
• Exercise equipment
• Javelins
Composite Sport Goods
Structural Applications: Beams,
Pipes, Channels, Bars, Rods
Fiberglass composite structural elements formed by pultrusion.
Composite in Marine Applications
Natural Fibers
• Straw Fibers : Rice, wheat/corn straws
• Bast : Kenaf, flax, jute, hemp
• Seed : Cotton
• Grass fibers : Bamboo, switch grass
• Wood fibers : soft and hard wood
Natural Fiber Composites
Pine Wood Fiber / Polypropylene
<
Jute Fiber / Polypropylene
(with black)
>
Pine Wood Fiber/
Polypropylene
<
Maple Wood Fiber /
Polypropylene (with black)
>
Pine Wood Fiber/
Polypropylene
>
Pine Wood Fiber/
Polypropylene
<
Maple Wood Fiber /
Polypropylene (with black)
>
Pine Wood Fiber/
Polypropylene
BRIEF OVERVIEWS OF
PMC, CMC, MMC
KEY STRUCTURAL POLYMER
MATRIX COMPOSITES
Fiber Matrix Resins
E-Glass Polyester, Epoxy, Vinyl Ester
S2-Glass Polyester, Epoxy
Graphite Epoxy, Bismaleimide, Polymide
Aramid Epoxy, Vinyl Ester
Boron Epoxy
ADVANTAGES OF POLYMER
MATRIX COMPOSITES
• Good inplane stiffness and strength
• Low density
• Ease of fabricability
• Relatively low cost
• Corrosion resistance
• Fatigue resistance
• Low coefficient of thermal expansion
• Electrically and thermally conductive and nonconductive
materials
• Creep and creep fracture resistance
• Relatively mature technology
• Excellent in-service experience
DISADVANTAGES OF POLYMER
MATRIX COMPOSITES
• Low Temperature Capability
– Epoxy- To 350°F
– Bismalemide- To 400°F
– Polyimide- To 550°F
• Moisture Sensitive (4% absorption)
• Outgassing (Moisture and Organics)
• Low through-thickness stiffness and strength
• Low transverse modulus and strength for unidirectional
composites
• Thermoset resin have poor impact resistance
• Require special processing equipment (Autoclaves,
Ovens, Hot Press, RTM Equipment etc.)
Key High-Performance Ceramic
Matrix Composites
Reinforcement Matrices
Graphite Fiber Carbon, Glass, Silicon Carbide
Silicon Carbide Fiber Glass, Silicon Carbide, Silicon Nitride
Alumina-Boria-Silica fiber Silicon Carbide
Alumina Fiber Glass, Silicon Carbide
Silicon Carbide Whisker Alumina, mullite
Advantages of Ceramic Matrix
Composites
• High stiffness and strength
• Low density vs. other high-temperature properties
• Excellent high-temperature properties
• Wear resistance
• High fracture toughness, impact resistance and thermal shock
• Improved crack resistance compared to monolithic ceramics
• Excellent corrosion resistance
• Some material and process are very low cost (e.g. fiber
reinforced cements)
• Potential for net shape fabrication
Disadvantages of Ceramic Matrix
Composites
• Complex processes for high-performance
materials
• Fiber-matrix interactions at high
temperature degrade fibers
• Limited number of materials available
• Immature technology
• High cost
Current Status of Ceramic Matrix
Composites
• Carbon/Carbon composites for low-stress,
thermal protection applications
– Reentry vehicle nose tips
– Rocket nozzles
– Aircraft brakes
– Space shuttle leading edges
• Silicon carbide whisker reinforced alumina
introduced for cutting tools and bearings
• Silicon carbide, silicon nitride, and aluminum
matrix composites are considered as candidate
materials for internal combustion engines, gas
turbines, electronics and surgical plants.
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Key Metal Matrix Composites
Reinforcement Matrices
Boron fiber Aluminum, Titanium
Graphite fiber Aluminum, Magnesium, Copper
Alumina fiber Aluminum, Magnesium
Silicon carbide fiber Aluminum, Titanium
Alumina-silica fiber Aluminum
Silicon carbide whisker Aluminum, Magnesium
Silicon carbide particulate Aluminum, Magnesium
Boron carbide particulate Aluminum, Magnesium
Alumina particulate Magnesium, Aluminum
Advantages of Metal Matrix
Composites
• High axial strength and modulus
• Wear resistance
• Some reinforcing fibers are inexpensive
• Casting in a low-cost, Net-shaped process
• High transverse and through-thickness strength and modulus
• Higher temperature capability than PMC
• Not moisture sensitive (except for corrosion)
• Low coefficient of thermal expansion
• High thermal conductivity
• High electrical conductivity
• Particulate and whisker composites
– Isotropic
– Standard metal-working processed
– Low cost reinforcements
Disadvantages of Metal Matrix
Composites
• Many fabrication processes are complex
and expensive
• Many reinforcing fibers are expensive
• Fiber-matrix interactions at high
temperature degrade fibers
• Machining difficult
• Technology relatively immature
Metal Matrix Composites Status
Continuous Fibers
• Very limited in aerospace structures
• Experimental structural and gas turbine engine
components
Discontinuous Fibers and Whiskers
• Discontinuous fibers used in internal combustion
engines
• Limited use in machine components
• Other applications under study
Metal Matrix Composites Status
(cont…)
Particles
• Widely used in
– Cutting tools
• Often called cermets
• E.G. Cemented Carbides- “Tungsten Carbide”
– Circuit breaker contacts
• Increasing Use in
– Machine components
– Process industries equipment
– Aerospace structures
– Electronic packaging
– Sporting goods
– Automobile mechanical components
• Brake rotors and drums
• Drive shafts
Structural composite materials ___Functional composite materials __
Other lm�rtant Applications
Metal Matrix Composites
Particles Fibers Sheets
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Applied Car Parts of Tokawhisker
(Tokamax) Reinforced Aluminum Alloys
Valve Rocker Arm made of FRM
Characteristics
- High Modulus and Strength
- Wear Resistance
- Release Weight
Piston for Heavy Duty Diesel Engine
made of Partially Reinforced Al-Alloy
Characteristics
- High Modulus and Strength
- Wear Resistance
- Thermal Shock Resistance up to 400°C
Connecting Rod made of FRM
Characteristics
- High Modulus and Strength
- Wear Resistance
- Heat Resistance
- Release Weight
Shift Fork for Engine
Transmission made of
FRM
Characteristics
- High Modulus and Strength
- Wear Resistance
- Release Weight