COMPOSITE MATERIALS

Prerequisite : Definition and basic understanding of composite materials.

 Constitution of composite materials- Matrix and Dispersed phase
 Classification of composite materials - Particle reinforced composites, Fibre reinforced
composites, structural composites
 Advantages and Applications of composite materials

A composite material can be defined as a combination of two or more materials that results in
better properties than those of the individual components used alone. In contrast to metallic
alloys, each material retains its separate chemical, physical, and mechanical properties. The two
constituents are dispersed phase (reinforcement) and a matrix phase. The main advantages of
composite materials are their high strength and stiffness, combined with low density, when
compared with bulk materials, allowing for a weight reduction in the finished part.
Composite material: A composite material is defined as a multiphase material that exhibits a
significant proportion of the properties of both the constituent materials as well as unique
properties of its own.
Constitution of composite material
Composite material consists of two phases. The continuous phase is the matrix phase and the
reinforcing or discontinuous phase is the dispersed phase.

a. Matrix phase: The continuous phase is the matrix, which is a polymer, metal, or ceramic.
Polymers have low strength and stiffness, metals have intermediate strength and stiffness but
high ductility, and ceramics have high strength and stiffness but are brittle.

Functions of matrix phase

In composite matrix play the major role to determine the end properties. The functions of matrix
phase are as follows:
i. Binds the dispersed phase together
ii. Acts as a medium for distribution of applied load to dispersed phase
iii. Keeps the reinforcing fibers in proper orientation for high strength development
iv. Prevents the propagation of cracks due to softness and plasticity

b. Dispersed phase: It is the structural constituent which determines the internal structure of
composite. Dispersed phase should have good compatibility with the matrix and there
should be strong interfacial bond between the dispersed and matrix phase. Otherwise the
composite will have low durability. Dispersed phase may be particulates (small pieces of
hard solid metallic or non metallic materials randomly distributed), fibres (long thin filament

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 with high length to diameter ratio) , flakes (thin solids having 2D geometry), whiskers (thin
strong filaments with extremely high length to diameter ratio) .

Characteristic properties of composite materials

Following are the characteristic properties of composite material:
i. High specific strength and specific stiffness.
ii. Lower electrical conductivity and thermal expansion.
iii. Maintains structure at high temperature.
iv. Can be fabricated easily and economically.
v. Better toughness, corrosion resistance, shock resistance.

Classification of composite materials

Reinforcing phase
The reinforcing phase provides the strength and stiffness. In most cases, the reinforcement is
harder, stronger, and stiffer than the matrix. The reinforcement is usually a fiber or a particulate.
Particulate composites have dimensions that are approximately equal in all directions. They may
be spherical, platelets, or any other regular or irregular geometry. Particulate composites tend to
be much weaker and less stiff than continuous fiber composites, but they are usually much less
expensive. Particulate reinforced composites usually contain less reinforcement (up to 40 to 50
volume percent) due to processing difficulties and brittleness.

Particle reinforced composites

Particle reinforced composites have particles of any shape or size but it should be equiaxed i.e:
the dimensions are nearly same in all directions and they should be evenly distributed throughout

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the matrix. The particles are added to the liquid matrix which is then solidified. The matrix as
well as the particulates shares the load bearing function. The matrix may be metals, ceramics or
plastics. These are the cheapest and most widely used.

Uses of particle-reinforced composites:

i. Such composites is used in cutting tools, drills etc.
ii. The composites is also used in rocket nozzles etc.

Particle-reinforced composites are divided into two categories depending on particle size.
(i) Large particle composites:
The particulate phase is harder and stiffer than the matrix. The particle size is more than one
micron, and the volume of the second phase is greater than 20 %. The strength of the bonding at
the particle matrix interface dictates the degree of reinforcement and the mechanical properties.
Examples of large particle composites are:
(a) Concrete: Both the matrix and the dispersed phase are ceramic materials. Matrix
phase is Cement and the dispersed phase is sand and gravel.
(b) Cermets: They are ceramic metal composites. They are of two types: (i) oxide
cermets: Al2O3 dispersed in Cr matrix. It has good strength and very good thermal
shock resistance. (ii) carbide cermets: Titanium carbide, Tungsten carbide,
Chromium carbide in Co or Ni matrix. They have high surface hardness, high
abrasion and corrosion resistance.
(c) Elastomers and polymers reinforced with particulate materials: Eg: carbon black
incorporated in vulcanized rubber. For significant reinforcement the particle size
must be small.
(ii) Dispersion strengthened composites :
Very small particles of range 10-100nm are used. The particle – matrix interactions leading to
strength occurs at the atomic or molecular level. In this the matrix phase is the major load
bearing constituent. Typical dispersion strengthened composites are alumina reinforced
aluminum and thoria (thorium dioxide) dispersed nickel.

Fiber reinforced composites

A fiber has a length that is much greater than its diameter. The length-to-diameter (l/d) ratio is
known as the aspect ratio and can vary greatly. Continuous fibers have long aspect ratios, while
discontinuous fibers have short aspect ratios. Continuous-fiber composites normally have a
preferred orientation, while discontinuous fibers generally have a random orientation.
Typical fibers include glass, aramid, and carbon, which may be continuous or discontinuous.
Fiber reinforced composites are made up of three components- polymer matrix, filament and a
bonding agent which ties the fiber with polymers. Commonly used fibers are glass or metallic.
The characteristics of fiber reinforced composites depends on (i) nature of fiber and matrix, (ii)
properties of fiber and matrix, (iii) relative volume fraction of fiber and matrix, (iv) orientation

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and distribution of fibers in the matrix phase, (v) length to diameter ratio of the fibers. (vi)
strength of interfacial bond between fiber phase and matrix.
Based on fiber orientation they are classified as : Continuous and aligned, discontinuous aligned
and discontinuous and random.

(i) Continuous and aligned composites:

The properties are highly anisotropic i.e; they depend on the direction in which they are
measured. The maximum strength and reinforcement is achieved along the direction of fiber
alignment. In the transverse direction the fiber reinforcement is virtually non existant and
fracture usually occurs under very low tensile stresses.

(ii) Discontinuous fiber composites:

The discontinuous fibers have low reinforcement efficiency than for continuous fibers.
Discontinuous and aligned composites have greater applications. Chopped glass fibers, carbon
and aramid fibers are employed. The fabrication cost is more for continuous and aligned.
Intricate shapes can be formed with discontinuous fiber composites but impossible with
continuous fiber composites.

Structural composites
A structural composite comprises of both homogeneous and composite materials. The properties
depend on the properties of the constituent materials and their geometrical design. They are
broadly classified as (i) laminar composites (ii) sandwich panels.

(i) Laminar composites:

A laminar composite consists of two dimensional sheets or panels that have preferred high
strength direction. The layers are stacked and then cemented together in such a way that the
orientation of high strength varies with each successive layer. Eg; plywood.

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Laminar composites may be constructed using fabric materials such as cotton, paper embedded
in a suitable plastic matrix. Laminar composites possess relatively high strength in a number of
directions in a 2-dimensional plane.

(ii) Sandwich panels:

It consists of two strong outer sheets called faces separated by a layer of less dense material
called core which is of lower strength and low stiffness.
Face materials – fiber reinforced plastics, plywood, Ti, steel Al alloys.
Core materials – synthetic rubber, foamed polymer, balsa wood.
Face bears the most of the in plane loading and any transverse bending stresses. Core separates
the faces and resists any deformations perpendicular to the face plane.
With increase in the thickness of core, its stiffness increases.

Properties of Structural composites:

i. Structural composites shows very high tensile strength
ii. The composites have very good resistance to abrasion and corrosion
iii. Structural composites shows good dimensional stability

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 iv. Structural composites have low density

Applications of Structural composites:

i. Structural composites are used in roofs,
ii. The composites can be used in floors
iii. The composites can be used in walls of buildings
iv. Structural composites are also used in airplanes

Applications of composite materials:

1) Marine applications like propellers, shafts, hulls etc.

2) Safety equipment like ballistic protection
3) Valves, pumps, floors, furniture, sports goods etc.
4) Components of aircraft, helicopters etc.

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