Chapter 1: Introduction to
Composite Materials
ME5353: Composite Materials
Rizwan M. Gul
UET Peshawar
Definition
▪ A definition is the most difficult thing for any term and this is
especially true for the composite materials
▪ A simple definition:
– Two or more materials combined together on a
macroscopic scale
▪ A more exact definition:
“Mixture of a combination of macro-constituents phases
composed of materials which are in divided state and
which generally differ in form and/or chemical
composition.”
Definition (contd)
▪ Structural level is important:
– At sub-microscopic level:
• Compounds and alloys can be considered composites
– At microscopic level:
• Multiple-phases and multi-crystal structures can be considered composites
– At macroscopic level:
• Real composites
▪ Other ways of looking at composites:
– Blending of two dissimilar materials to get characteristic of both blended
materials
– Combining materials with combination of properties that cannot be achieved
with either of constituted acting alone
– Designing rather than selecting materials
Composite Materials
Composite Materials
Evolution of Engineering Materials
Composite Materials
▪ A simple model:
Reinforcement
Matrix
▪ Constituents Materials for Composites:
• Reinforcement: the strengthening agent
Can be in the form of Fibers or Particles
• Matrix: the main body
Can be polymer, metal or ceramic
• Interface: the bonding area between the reinforcement and matrix
Classification of Composites (I)
▪ Natural Composites:
– Wood (Cellulose & Lignin), Bones
▪ Synthetic Composites:
– Traditional/Old Composites: Bricks of mud and straw
(straw provide reinforcement and the
moisture is diffused so it dries uniformly
and cracks do not propagate)
Swords of Japanese Samurai Warriors
(Carbon is diffused in the iron sheet; which
was folded several times to get a laminar
structure)
– GFRP (Fiber Glass), CFRP, AFRP
“You are no longer to supply the people with straw for making
bricks; let them go and gather their own straw” - Exodus 5.7.
CLASSIFICATION OF COMPOSITES BASED ON
MATRICES (II)
Composites are classified into three categories, namely:
1. Polymer Matrix Composites (PMCs),
2. Metal Matrix Composites (MMCs),
3. Ceramic Matrix Composites (CMCs).
CLASSIFICATION OF COMPOSITES BASED ON
REINFORCEMENTS (III)
Based on Reinforcement, there are five
types of Composites:
1. Fiber Composites:
– primary load bearing component
2. Particulate Composites:
– mainly MMCs
3. Laminar Composites:
– plywood, glass plastic laminates
4. Flake Composites:
– Moisture resistant, high
thermal/electrical resistance
5. Filled/Skeletal Composites:
– Continuous 3-D skeletal matrix
impregnated with a second phase
filler materials
– Filled honeycomb/filled sponges
TYPES OF COMPOSITES BASED ON REINFORCEMENT
(III)
Fiber Composites
▪ Among the different composites, Fiber Composites are the most important
and will be our main discussion topic
▪ In fiber composites, fiber provides strength and matrix transmit load, bond
fibers and protect them
– Hard and strong fibers are generally brittle
– Matrix on the other had are soft have low yield strength and are tough
– Combination: High strength fibers encased within tough matrix
TYPES OF FIBER COMPOSITES
1. Continuous Fiber Composites,
2. Short Fiber Composites.
a) Random,
b) Oriented.
RANGE OF MODULI FOR VARIOUS COMPOSITES
PROPERTIES OF COMPOSITES
▪ The performance depends on:
1. The constituent materials
2. The form and arrangements of constituents
3. The interaction between the constituents (interface)
▪ Different properties of composites can be:
1. Determined by rule of mixture, e.g. density
2. Each constituent may contribute to a particular desired property, e.g. a
corrosion resistant layer
▪ The properties of composites depend on:
1. the constituent materials
2. the form and structural arrangements (orientation) of constituents
3. the interaction between the constituents
SIGNIFICANCE OF COMPOSITE MATERIALS
Potential advantages of composite materials include:
1. High Stiffness to Weight Ratio
Light Weight
2. High Strength to Weight Ratio
3. Corrosion Resistance
4. High Heat Distortion Temperature
5. Vibrational Dampening
6. Low Cost
7. Ease of Manufacturing
CHARACTERISTICS OF POLYMER COMPOSITE MATERIALS
Advantages Limitations
Excellent strength : weight and outstanding Stiffness of GRP composites can be low in
stiffness : weight ratios for advanced relation to metals, but can be improved by
composites stiffening techniques (ribs, corrugation,
sandwich structures, advanced fiber
reinforcement)
Properties can be varied according to design Properties tend to be anisotropic, although this
requirements should be design-in
Inert to most acids and alkalis Susceptible to splitting and delamination
Versatile low-cost fabrication techniques – Most polymer composites limited to use below
elimination of conversion stages 150°C (260°C for special grades)
All composites have high damping capacity Degraded by water and solvents
Honeycomb sandwich construction offers good Carbon fibre based materials are
insulation and good resistance to fatigue, sonic electrolytically positive and require isolation
fatigue and vibration loading from any adjacent metals (usually by thin GRP
layer)
CFRP laminates have outstanding resistance
to fatigue loading Very high raw materials cost (advanced
composites
CFRP laminates display good friction and wear
characteristics
Zero or negative expansion coefficients
possible for advanced composites in certain
fibre orientations
APPLICATIONS OF COMPOSITES (I)
▪ Aero-space:
– Used in both primary (necessary for flying like stabilizers, rudders and fuselage)
and secondary structures (like ducts, seats)
– Composites more used in military than civil?
▪ Automotive:
– Corvette, SMC Body Panel, Leaf springs
▪ Boats:
– Monopoly on small and medium sized because combine all advantages: light
weight, ease of manufacture, and corrosion resistant
▪ Sports
– Fishing Poles, Skis, Tennis Racket Handle, Golf Club Shafts, bicycle frame,
helmets
APPLICATIONS OF COMPOSITES (II)
▪ Chemical Industry (corrosive environment):
– Tanks and Containers, Pipes
▪ Medical:
– Light weight mechanical support and equipment for disabled, Prosthetic
Devices
▪ Ballistic:
– Bullet Proof Jackets
APPLICATIONS OF FIBER REINFORCED COMPOSITES
Application Area Typical Examples Reasons for use
Aerospace Very wide range of High strength weight
applications including and stiffness: weight
primary structure, e.g. taiL justify cost of
plane on airbus and Boeing materials.
777 and complete wing Ability to be
sections on AV8-B. economically
Outer Wing panels on fabricated into
ATR72. complex shapes for
low production totals.
Sports and leisure goods Gold club shafts (CFRP), Light Weight
Badminton and tennis High Stiffness
racquets (laminated wood, Low friction and wear
CFRP), Prestige value
Skis (CFRP/GRP),
Canoes, kayaks, high
performance sailing craft
(carbon/glass,
carbon/Kevlar, Kevlar).
Transport Critical, primary load bearing Need to reduce
components under weight to conserve
evaluation (e.g. drive shaft, energy.
chassis floor pan).
APPLICATIONS OF FIBER REINFORCED COMPOSITES
Application Area Typical Examples Reasons for use
General Engineering Textile machinery (CFRP). Reduction of
momentum and
inertia in
reciprocating and
rotating
components
(light weight).
Cigarette manufacture – Good wear
filter tip distributor properties.
(chopped carbon fiber
reinforced nylon 6,6).
Touch switches (carbon Conductivity.
fiber-reinforced
polycarbonate).
Pumps, impellors, chemical Inertness.
plant (may be carbon or
carbon/glass).
Gauges and templates Low thermal
(carbon). expansion,
lightweight.
Medical Appliances Surgical implants (carbon, Chemically inert
Kevlar, textiles). Weight reduction
Easy to mould of
metal
May promote
healing.
Atomic Plant Low neutron
capture cross-
section.
APPLICATIONS OF COMPOSITES
High Modulus:
Carbon and other fibers
Low Modulus:
Glass and similar fibers
Candidate Materials for Civil Aircraft Structure
Candidate Materials for Military Aircraft Structure
A320/319 Composite Structures
A380 Composite Structures
COMPOSITE MATERIALS IN BOEING 575
COMPOSITE ROTOR BLADE FOR WESTLAND SEA KING
HELICOPTER
Global Hawk UAV
Composites in Wind Turbines
Standard: rotor blades of glass fibres
Future: rotor blades of carbon fibres
COMPOSITE MATERIALS IN FISHING RODS
Composites Materials in Sports
COMPOSITE MATERIALS IN VAULTING POLES
• Light weight
• Must not Buckle
• No plastic deformation
• Should be stiff
Pressure Vessels and Boats
Prosthetic Devices
Train Cabins
Automobiles
Corvette Leaf Spring
ME5353: Composite Materials
Rizwan M. Gul
UET Peshawar
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