CHAPTER 25
COMPOSITES:FIBROUS,
PARTICULATE AND FOAMED
Introduction
Thc word "composites" has a modern ring. But usingthe high strengthof libres to stiffen
a n d s t r e n g t h e na c h e a pm a t r i x m a t e r i a li s p r o b a b l yo l d e r t h a n t h e w h e e l .T h e P r o c e s s i o n a l
Wav in ancient Babylon. one of the lesserwonders of the ancient world, was made of
bitumen reinforced with plaited straw. Straw and horse hair have been used to reinforce
mud bricks (improving their fracture toughness) for at least 5000 years. Paper is a
compt'lsite:so is concrete;both were known to the ancient Rtlmans. And almost all natural
m a t e r i a l sw h i c h m u s t b e a r l o a d - w o o d . b o n e . m u s c l e - a r e c o m p o s i t e s .
T h e c t t m p o s i t ei n d u s t r y .h o w e v e r .i s n e w . I t h a sg r o w n r a p i d l y i n t h e p a s t3 0 y e a r sw i t h
thc ricvelopmcnt of Jibrous compo,siles:to begin with. g/ass-librereinforced polymers
(GF If P trr fibrcqlass)and. more recentl;;.ci;rbon-f,brereinforcedpolvnters(CFRP). Their
u s e i n b t t a t s .a n d t h c i r i n c r e a s i n gr e p l a c e m e n o t f m e t a l si n a i r c r a f t a n d g r o u n d t r a n s p o r t
s v s t e m s i,s a r e v o l u t i o ni n m a t e r i a lu s a g ew h i c h i s s t i l l a c c e l e r a t i n g .
Compositcs need not be made of fibres. Plywood is a lamellar composite. giving a
m a t e r i a lw i t h u n i f o r m p r o p e r t i e si n t h e p l a n eo f t h e s h e e t( u n l i k e t h e w o o d f r o m w h i c h i t
i s m a d e ) . S h c e t so f G F R P o r o f C F R P a r e l a m i n a t e dt o g e t h e r ,f o r t h e s a m er e a s o n .A n d
sandrvichpancls---compositcsmade of stiff skins with a low-densitycttre-achieve special
p r o p c r t i c sb v c o m b i n i n g .i n a s h c c t ,t h c b e s tf e a t u r e so f t w o v e r y d i f f e r c n t c o m p o n c n t s .
Cheapest of all are the purticulutecontposites.Aggregate plus ccnlcnt sives concrctc.
a n d t h e c o m p o s i t ei s c h e a p c r( p c r u n i t v o l u m e ) t h a n t h e c e m e n t i t s e l f . P o l y m c r sc a n b e
f i l l c d w i t h s a n d .s i l i c af l t r u r .t t r g l a s sp a r t i c l e s .i n c r e a s i n gt h e s t i f f n e s sa n d w c a r - r g s i s t a n c e .
a n d o f t c n r c d u c i n gt h e p r i c e . A n d o n c p a r t i c u l a t ec o m p o s i t c .t u n g s t e n - c a r b i dpea r t i c l e si n
" h a r d m e t a l " ) , i s t h e b a s i so f t h c h e a v v - d u t y
c o b a l t ( k n o w n a s " c e m e n t e dc a r b i d c " o r
c u t t i n gt ( ) 0 1i n d u s t r y .
But high stiffnessis not always rvhat you want. Cushiclns,packagingand crash-padding
r e q u i r c m a t c r i a l sw i t h m o d u l i t h a t a r e l o w e r t h a n t h o s eo f a n y s o l i d .T h i s c a n b e d o n e w i t h
lbums----ct'ul positcstlf a solid and a gas-rvhich have propertieswhich can be tailored, with
g r c n t p r c c i s i o n .t o m a t c h t h c e n g i n c c r i n gn e e d .
W c n r l w c x a m i n e t h c p r o p c r t i c so f f i b r o u sa n d p a r i c u l a t c c o m p o s i t c sa n d f o a m s i n a
l i t t l c m t l r c t l c t a i l . W i t l r t h c s c m a t c r i a l s .m o r e t h a n a n y o t h e r . p r o p c r t i e sc a n b c d e s i g n e d -
,I
&t
i n : t h c c h a r a c t c r i s t i cosf t h c m a t e r i a li t s c l fc a n b e c n g i n e e r c d .
2.1I
11")
-t- ENGINEERING MA]'[,RIAI,S
Fibrouscomposiles
P o l v n r e r sh u v c a l o u ' s t i f l n c s s , a n d ( i n t h e r i g h t r a n g c o l t c m p c r a t u r c ) a r c d u c t i l c .
C c r a n r i c sa n d g l a s s c sa r e s t i f f a n d s t r o n g , b u t a r e c a t a s t r o p h i c a l l vb r i t t l e . l n J i b r o u s
c o n t p < t s i l ewsc c x p l o i t t h e g r c a t s t r e n g t ho f t h e c e r a m i cw h i l c a v o i d i n gt h e c : l t a s t r o p h :et h c
b r i t t l e f a i l u r eo f f i b r c sl c a d st o a p r o g r e s s i v en, o t a s u d d e n ,f a i l u r e .
I f t h c f i b r c so f a c o m p r . r s i taer e a l i g n e da l o n gt h c l o a d i n gd i r e c t i o n ,t h c n t h e s t i f f n c s sa n c
t h c s t r c n g t h : r r e. r o u { h l t , s p e a k i n g ,a n a v c r a g eo f t h o s eo f t h c m a t r i x a n d { i b r e s .w c i g h t c d
b r t h c i r v o l u n r cf r u c l i o n s .B u t n o t a l l c o m p o s i t cp r o p c r t i c sa r c i u s t a l i n c a r c o n r b i n u t i o no f
t h o s c o l ' t h c c o r u p o n c n t sT. h c i r g r c a t a t t r a c t i o nl i c s i n t h c l ' a c tt h a t . f r c q u en t l r ' . s o r l c l h i n g
c x t r ai s q a i n c d .
T h c t o u g h n c s si s a n c x a n t p l e .I f a c r a c k s i m p l l ' r a n t h r o u g h ; r G F R P c o r l p o s i t c . o n e '
n i g h t ( a t l i r s t s i g h t ) c x p c c t t h e t o u g h n e s s1 o b e a s i m p l eu ' e i g h t c da v c r a e co f t h a t o f g l a s s
a n d c p o x r ' :a n d b o t h a r e l o w . B u t t h a t i s n o t w h a t h a p p e n s .T h e s t r o n gf i b r c sp u l l o u t o f t h c
e p o x ) ' . l n p u l l i n g o u t . $ ' o r k i s d o n e a n d t h i s w o r k c o n t r i b u t e st o t h c t o u g h n c s so f t h c
c o m p o s i t e. T h e t o u g h n e s si s g r e a t e r - - - o f t e nm u c h g r e a t c r - t h a n t h c l i n c a r c o m b i n a t i o n .
P o l v m c r - m a t r i x c o m p o s i t e sf o r a e r o s p a c ea n d t r a n s p o r t a r e m a d c b v l a v i n g u p g l a s s .
c a r b o nt ' r rK c v l a r f i b r c s( T a b l e2 5 . 1 )i n a n u n c u r e dm i x t u r eo f r e s i na n d h l r r d c n c r .T h c r c s i n
c u r c s . t a k i n g u p t h c s h a p eo f t h e m o u l d a n d b o n d i n g t o t h c f i b r c s . N , l a n vc o n r p o s i t e sa r c
b a s e do n c p o x i e s .t h o u g h t h e r e i s n o w a t r e n d t o u s i n gt h e c h e a p c rp o l l ' e s t c r s .
L a f i n g - u p i s a s l o w . l a b o u r - i n t e n s i v ej o b . I t c a n b e b y - p a s s c db , vu s i n g t h c r m o p l a s t i c s
c o n l a i n i n gc h o p p c df i b r e su ' h i c hc a n b e i n j e c t i o nm o u l d ed . T h e r a n d o m c h o p p e df i b r c sa r c
n o t q u i t e a sc f f e c t i v ea s l a i d - u pc o n t i n u o u sf i b r e s .w h i c h c a n b e o r i e n t e dt o m a x i m i s ct h ei r
c o n t r i b u t i o nt o t h e s t r e n g t h .B u t t h e f l o w p a t t e r n i n i n j e c t i o n m o u l d i n g h c l p s t o l i n e t h e
fibresup, so that clever mould designcan give a stiff . strong product. The techniqueis used
increasinglvfor sports goods (tennis racquets, for instance)and light-weight hiking gear
( l i k e b a c k - p a c kf r a m e s ) .
Making good fibre-compositesis not easy; large companics have been bankrupted b-v
t h e i r f a i l u r et o d o s o . T h e t e c h n o l o g yi s b e t t e r u n d e r s t o o dt h a n i t u s c d t o b e : t h e t r i c k sc a n
b e f o u n d i n t h e b o o k s l i s t e du n d e r F u r t h e r r e a d i n g .B u t s u p p o s cy o u c a n m a k e t h e m . v o u
s t i l l h a v et o k n o u ' h o w t o u s et h e m . T h a t n e e d sa n u n d e r s t a n d i n go f t h c i r p r o p e r t i e s .u ' h i c h
we examine next. The important properties of three common composites are listed in
Table 25.2. where they are compared with a high-strength steel and a high-strength
aluminium allov of the sort used for aircraft structures.
TABLE 25.I
Pnoppnnrs oF soME FIBRES AND MATRICES
Fibres
Carbon. T1'pe I l.95 390 2200
Carbon.Type 2 1.75 250 2700
C e l l u l o s ef i b r e s l.or 60 1200
G l a s s( E - g l a s s ) 2.56 76 1400-2500
Kevlar 1.45 125 2760
Matrices
Epoxies t.2-1.4 2 .1 - 5 . 5 40-85
Polyesters 1.1-1.4 1.4.5 45-85
COMPOSITES: FIBROUS. PARTICULATE AND FOAMED 243
€o\
8 R3
r\o€
alr
o
cO€O C-6
r , H o O d
o. ri rcj
c t a l h N N
g
q
:
t 2 7
6 -
I
- r € , C !
I I II C N
: { < a!al
; a z o.?
;I
c t 4
{
r,F
r r o
Ao: x x
m = 6 z o a i N -i4
< :
F i " D b
7.
6 ) - ' c r -
r c = r
al
C C -
& > Ec')
a
A>
u -
'.:
> a c
cl Eol
EEE =
#;Eii?
sar;c
sg5
1 A a EN(;INE[,RING MAT'ERIAI,S
t f t
High
modulus
o o o o o
o o o o o
(bi o o
o o o
O O O O O
mooutus o o o o o
o o O o o
O O O O
o o o o o
t l
--'-\ Hrgh
(c) Low modulus
modulus
F i g . 1 5 . 1 . 1 s )\ ' h e n l o a d e d a l o n g t h e 6 b r e d i r c c t i o n t h e f i b r e s a n d m a l r i x o f a c o n t i n u o u s - f i b r ec o m p o s i t cs u f f e r
c q u a l s t r a i n s .( b ) t A ' h c nl o a d e d a c r o s st h e f i b r e d i r e c r i o n .t h e f i b r e sa n d m a t r i x s c er o u g h l l ' e q u a l s t r e s s ;p a r t i c u l a t c
c o m p o s i t e sa r e t h e s a m e - ( c ) A 0 - 9 0 " l a m i n a t e h a s h i g h a n d l o u m o d u l u s d i r e c t i o n s ; a 0 - { 5 - 9 0 - 1 3 5 ' l a m i n a t e i s
ncarll isotropic.
Modulus
Whentu,olinear-elastic (thoughu'ithdifferentmoduli)aremixed,themixture
materials
The modulusof a fibrouscompositewhen loadeda/ongthe fibre
is also linear-elastic.
direction(Fig.25.1a)is a linearcombinationof that of the fibres, E1,andthe matrix.E'
E4;,=V1E7+ (1 - V)E^ (2s.1)
*'hereV, is thevolumefractionof fibres(seeBook I , Chapter6). The modulusof thesame
matcrial,loaded thefibres(Fig.25.1b)is muchless-it is only
across
tr =!\-*l-v,J-'
-': /'r5 l)
l4 E,, )
(sceBook 1, Chapter6 again).
Table 25.1 givesEr and E^ for commoncomposites.The moduli 811and E- for a
compositewith, say,50% of fibres,differ greatly:a uniaxialcomposite(one in whichall
anisotropic.By usinga cross-weave
tbe fibresare alignedin one direction)is exceedingly
of fibres(Fig.25.1c)the moduliin the0 and90odirectionscanbe madeequal,but thoseat
45oarestill very low. Approximateisotropycanbe restoredby laminatingsheets,rotated
through45o,to give a ply'u'ood-likefbrelaminate.
COMPOSITES: FIBROUS, PARTICULATE AND FOAMED 245
S t r a r nr ' '
curveof a conrinuous
Fig.15.2.The srress-srrain fibrecomposite (heavyline).sho.wing howit relatesto thoseof
thl fibresandthe matrix(thin lines).At the peakthe fibresareon thepointof failing.
V o l u m ef r a c t r oont l i b r e sl V . )
F i g . J 5 . 3 . T h c v a r i a t i o n o fp c u k s t r c s s w i t h v o l u n r c f r a c t i o n ol ifb r c s . . \ m i n i m u m v o l u m c f r a c t i t r n ( 7 r , , , , ) i s n e c d c d
t r )q i v c { n v s t r c n t t h c n i n g .
?16 ENGINT[,RIN(iMATERIALS
T h e f o r c e o n t h c f i b r c t h u s i n c r c a s c sf r o n r z e r o a t i t s e n d t o t h e v a l u e
fr
F= | rdo",'dr=ndo'l'x (2.5.6)
,l 0
z t !a d i s t a n c c- r f r o m t h c c r : r ! T l r r ' f o r c c r v h i c hu ' i l l j u s t b r c a k t h e f i b r e i s
F, = T o',. ra57)
+
Equating thesetwo forces. u'c find that the fibre u'ill break at a distance
t f
d o i
'
\ " . = - i (2s.
s)
I d'.'
f r o m i t s e n d . I f t h e f i b r e l e n g t h i s l c s st h a n 2 - r , .t h e f i b r e s d o n o t b r e a k - b u t n o r d o t h e y
c a r r ) 'a s m u c h l o a d a s t h c v c o u l d . I f t h e i ' a r c n r u c hl o n g c r t h a n 2 r , . t h e n n o t h i n gi s g a i n c d
b , vt h e c x t r a l c n g t h . T h e o p t i m u m s t r e n g t h( a n d t h e m o s t c f f c c t i v e u s e o f t h e f i b r e s ) i s
F4 1 Frbre
=
c
c
o D i s t a n c e( x ) |
F i g . 2 - 5 . 4 .L o a d t r a n s f e r f r o m t h e n r a t r i l t o t h c f i b r e c a u s e st h e t e n s i l e s t r e s si n t h e f i b r e 1 < rl i s e t o a p e a k i n t h c
m i d d l e . I f t h e p e a k e x c e c d st h e f r a c t u r e s t r c n g t h o f t h e f i b r e , i t b r e a k s .
f,
*
#
C O M P O S I T E S :F I B R O U S . P A R T I C U L A T E A N D F O A M E D 247
*'
f
$
]E
{
i
:
l!
Compresston
t h a n t h a t f o r f a i l u r ci n l c n s t t r n '
F i g . 1 5 . 5 .C o m p o s i r e sf a i l i n c o m p r e s s i o nh 1 -k i n k i n g .u t a k r a d* h i c h i s l o $ c r
stresscarried
obtained by chopping them to the length 2x,.in the first place' The average
b y a f i b r ei r i h e n i i h p i y o l l 2 a n d t h e p e i k s t r e n g t h( b y t h e a r g u m e n d
t e v e l o p e de a r l i c r )i s
T h i s i s m o r e t h a n o n c - h a l fo f t h c s t r e n g t ho f t h c c o n t i n u o u s - f i b r e m a t e r i a l( e q n . 3 5 . 3 ) .O r
i t i s i f a l l t h e f i b r c sa r e a l i g n c da l o n g t h c l o a c i i n sc l i r c c t i o n T . h a t . o f c o u r s c .w i l l n o t b e t r u e
in a chopped-fibre c o m p c i s i t .
e I n a i a r h o i l y ' f
. o r i n s t a n c e t
. h c f i b r e sa r e r a n d o m l yo r i e n t e d
in the p f a n eo f t h c p a n e l .T h c n o n 1 1 a" f r a c t i o no f t h e m - a b o u t l - a r c a l i g n e ds o t h a t m u c h
t e n s i l ef o r c e i s t r a n s f e r r e d t o t h e m , a n d t h e c o n t r i b u t i o n s o f t h e f i b r e st o t h e s t i f f n e s sa n d
s t r e n g t ha r e c o r r e s p o n d i n g l y r e d u c e d '
T h e c o m p r e s s i v es t r e n g i ho f c t t m p o s i t c si s l e s st h a n t h a t i n t c n s i o n .T h i s i s b e c a u s et h c
f i b r e sb u c k l e o r . m o r c p r e c i s e l - "t-h. c . r ' k i r r A - as o r t o f c o - o p r ' r a t i v cb u c k l i n g .s h o w ni n F i g .
2 - 5 . 5S . o w h i l e b r i t t l c c i ' r a n r i c sa r e b c s t i n c o m p r e s s i ( ) nc.( ) m p ( ) s i t cisl r c b e s t i n t c n s i t l n '
Toughness
T h e t o t t g h n e sG s , .o f a c o m p t t s i t e( l i k e t h a t o f a n y o t h c r m a t c r i a l ) i s a m c a s t l r co f t h e
energy absorbed per unit crirck arca. If the crack simpl-vpropagated straight thrtlugh the
s T ) a n t l f i b r e s ( t o u g h n e s sG l ) . w e m i g h t e x p c c t a s i n r p l c r u l e - o f -
m a t r l i ( t o u g h n e s .G
mixtures
/')<
c.- ! / l -
B u t i t d t t e sn o t u s u a l l yc l ot h i s . W c h a v c a l r e a d ys c e nt h a t . i f t h c l c n g t h o f t h c f i b r c si s l c s s
t h a n 2 x , . .t h e y w i l l n o t f r a c t u r c .A n d i f t h c . vd*o n ( ) tf r a c t u r ct h c , vm u s t i n s t c a dp u l l t l u t a s t h c
c r a c ko p e n s( n i g . Z S . O yT. h i s g i v c sa m a j o r n c w c o n t r i b u t i o nt o t h c t o u g h n c s sI.f t h c m a t n x
s h e a rs i r e n g t h i s g - i ' ( a s b c f o r e ) , t h c n t h c w o r k d o n e i n p u l l i n g a f i b r c o u t o f t h c f r a c t u r e
surfacc is given approximately b-v
tll
,i.
.{:
,i
.1;
,,i
i
:,
F i g . 1 5 . 6 . F i b r e s t o u g h c n b v p u l l i n g o u t c r fr h c l r a c t u r c s u r f a c e .a b s o r b i n gc n e r g ] a s t h e c r a c k o p c n s
tr
G,=ndo!'^-t"ll1i.:LuTt. (2s.12)
d id- :d #
'1
Optimum Optimum
Mode of loading stranolh
FI
Et' t-
.
1y = ptr? 14 = ptt?
= lrrF\rr / u \
= F ll : J
\;/ E ' (rv
E
Maxrmise Maximise !
;
4Fll orl
Ef t-
,(
1y1= plt?
/'/ €>l -
- "- t I il-l I -r'
l l '- c' r
= rtorrt"il,r.
1 -
i'
d lfu
E
}1 Maximise- M a x i m i s e!
BEAM It p
^ 5Fl3 3Fl
D = :::---:" ''Y -
JIEWI- 4 *t.
-22,T>i:;io"'".
K\, rl;I\r : t.l - tl
\ 3 2 6 1 tr t
3Fl'w 1l rr
4 l\ ;i'
PLATE
f-$/' E "
M a x r m i s -e
p
M a x i m l s ed
I
E - Y o u n g s m o d u l u s ; ( t v = Y i e l d s t r e n g t h ;t ) = D e n s r t y
d e f e c t i o nf o r a g i v e nw c i g h l i s t h i . l tm a d eo f a m a t e r i a lw i t h a m a x i m u m E / p ( t i e si n t en s i o n) .
t
E I : / p ( b c a m i n b e n d i n g )o r E t l p ( p l a t ei n b e n d i n g ) .
W h e n E / p i s t h c i m p t ' r r t a n tp a r a m e t e r , t h e r e i s n o t h i n g t o c h o o s e b e t w e e n s t c c l .
a l u m i n i u m o r f i b r e g l a s s( T a b l e 2 5 . 2 ) . B u t w h e n E r l r / p i s c o n t r o l l i n g ,a l u m i n i u m i s b e t t e r
r h a n s r e e l :t h a t i s w h y i t i s t h e p r i n c i p a l a i r f r a m e m a t e r i a l . F i b r e g l a s si s n o t s i g n i f i c a n t l y
b e t t e r . O n l y C F R P a n d K F R P o f f e r a r e a l a d v a n t a g e .a n d o n e t h a t i s n o w e x p l o i t e d
e x t e n s i v e l yi n a i r c r a f t s t r u c t u r e s T. h i s a d v a n t a g ep e r s i s t sw h e n E l ' ' l l p i s t h e d e t e r m i n i n g
quantity-and for this reason b o t h C F R P a n d K F R P f i n d p a r t i c u l a ra p p l i c a t i o ni n f l o o r
p a n c l sa n d l a r g el o a d - b c a r i n gs u r f a c e sl i k e f l a p sa n d t a i l p l a n e s .
I n s o m e a p p l i c a t i o n si t i s s t r e n g t h .n o t s t i f f n c s s t. h a t m a t t e r s .F i g u r e2 5 . 7s h o w st h a t t h e
c o m p o n e n tw i t h t h c g r c i l t e s ts t r e n g t hf o r a g i v e nw e i g h t i s t h a t m a d e o f t h e m a t e r i a lw i t h a
m a x i m u m r r , / p ( t i c s i n t c n s i o n ) . r r ; ' r l p l b e a m s i n b e n d i n g ) o r o l . ' 2 l p( p l a t e si n b e n d i n g ) .
E v e n w h e n c , l p i s t h e i m p o r t a n t p i l r a m e t e r .c o m p o s i t e sa r e b e t t e r t h a n m e t a l s ( T a b l c
2 5 . 2 ) .a n d t h e a d v a n t a g eg r o w sw h c n o | l l p o r o l . ' 2 l pi s d o m i n a n t .
D c s p i t e t h e h i g h c o s t o f c o m p o s i t e s t. h e w e i g h t - s a v i n gt h e y p e r m i t i s s o g r e a t t h a t t h e i r
u s e i n t r a i n s . t r u c k s a n d c v e n c a r s i s n o w c x t c n s i v e .B u t . a s t h i s c h a p t e r i l l u s t r a t e s .t h e
e n g i n e e rn e c d s t o u n d c r s t a n dt h c m a t e r i a l a n d t h e w a y i t w i l l b e l o a d e d i n o r d e r t o u s e
c o m p o s i t c sc f f c c t i v c l y .
THE PHYSICAI- ']ASIS OF YOI.-ING'S I\IODUT-I'JS
59
(o)
T S t r o i nc " = f
_l-u e q u o li n f i b r e s
(f )ond motrix
(m)
I
I
i
S t r e s se q u o l I n
m
fibres(f)ond
m o t r i x( m )
f
t
o
+ (1 - Vp)e._
en: Vsens
Vp rl-%\
:---+l ' \ E_^ l o .
Ef /
The modulus, as before, is cyle^ so that
E "o.*"',.
(Porticulole
upper eslrmole composites)
o u r '
while. Naturally
increase in stiffness that adding particles gives is economically worth
particulate composite is isofropic, rather than anisofropic as would be the
the resulting
composites; and this, too, can be an advantage' These
case for the fibre-reinforced
and moulded by normal methods (most fibre-composites
filled polymers can be formed
recent models of cars
.unnotl and so are cheap to fabricate. They are appearing in very
as bumpers, grilles, and protective trim (filled polypropylene is the commonest)'
SummarY
The moduli of metals, ceramics and glassy polymers below T6 reflect the stiffness of
leathers'
the bonds which link the atoms. Glasses and glassy polymers above T6 are
rubbers or viscous liquids, and have much lower moduli. Composites have moduli
which are a weighted average of those of their components'
Further reading