*Callister
Two different materials that have different characteristics are
combined together, Multi-phased materials. Both constituents
contribute to the properties of the final material.
Wood is a cellular material where the cells have cellulose fibres that
grow in a similar direction. It is a natural composite. Fibres will give
the strength and the stiffness to the wood. Another example is
reinforced concrete is very strong in compressions however it has
poor behaviour when it is under tension. Another natural composite
is bone. It includes fibres and minerals that give the toughness of
our bones.
Steel with the eutectic composition that includes
pearlite: ferrite and cementite that are 2 dissimilar phases, however
this is not considered as a composite. Composites are artificially
made and they are not the result of a homogenous melt.
They are a new class of materials: fibreglass materials. These
composite materials that are used for structural materials have a
very high strength to weight ratio and a very high stiffness to weight
ratio. The common problem is that strong materials are usually high
in density and are heavier. The use of composites was quite
restricted because little knowledge was known regarding such
materials as opposed to metals. Composite materials even for the
simple class the ones that are easy to produce are still very
expensive. The idea was to use them where the cost of production
would justify their use. In the car industry they are getting more
popular due to their weight saving property. Are also used in the
marine industry since they do not corrode and rot. A layer of gel
coat is normally used to protect the composite from UV radiation.
The properties are generally anisotropic; their properties differ in the
direction of the fibres. They are less ductile which can cause
problems with large loadings. They are found not to be too
susceptible to fatigue. When it comes to aerospace, their fatigue
performance is not a critical design factor like in metals. They have
advantages in corrosion and fatigue. However, they can be affected
by moisture and their polymer resistance temperature is much less.
Fibre reinforced dental resins-polymer composite that is stronger
and much more susceptible to failure. Dentures undergo a lot of
masticating forces that is a lot of fatigue stress. Research is being
conducted to improve dentures from failing such as tubes with liquid
resin that leaks when the denture is damaged.
The main property determining factors of composites:
The properties of the matrix and the dispersed phase
*Slide 22- stresses in fibres and matrix. The fibre can take most of
the load due to its stiffness. The strength and stiffness are highly
dominated by the fibre. Lc is the length of fibre required to reach the
maximum stress before fracture. If the matrix reaches the shear
strength it will shear.
*Slide 24 critical length equation
*Slide 26 4 different composites and their respective critical lengths
and length to diameter ratios. Longer fibres result in more difficult
and costly processing.
A fibre composite where the fibres are continuous and aligned: The
fibre reinforcement is at its maximum in one direction and zero in
the transverse direction. The properties are highly anisotropic.
*Slide 28- the matrix is ductile, the stiffness of the matrix is lower
than that of the fibre, and the fracture strain of the matrix is higher
than the fracture strain of the fibre. The fibre is brittle and higher in
tensile strength and stiffness.
Initially during stage 1 of deformation the composite is pulled and
the matrix and fibres are both being strained at equal amounts:
isostrain in an elastic fashion. Then in stage 2 as the load is
increased the fibres will continue to stretch elastically while the
matrix will start to deform plastically. A certain strain is reached
which is equivalent to the maximum fibre strain and the fibres start
to break. This is the onset of composite failure. The matrix can take
the load and redistribute it to other fibres; therefore the failure
would not be catastrophic. At failure point the total stress within the
composite is the stress multiplied by the volume fraction of the
matrix. *See slide 29 and worked examples in Callister.
The modulus of the composite when loaded in a transverse direction
to the fibres see slide 30. Weak bonding will translate into lower
strength-slide 31. The properties of the composites of slide 32 are
highly anisotropic. An epoxy matrix and the fibre is a polymer-Kevlar.
In the transverse direction the Kevlar is acting as a negative
reinforcement.
Discontinuous and Aligned Fibre Composites less than 15
times the critical length are easier to process and there are more
techniques, which can produce them and can yield cheaper
products.
Less strength than the continuous aligned fibre
composites: since the fibres are short and therefore fewer fibres are
available to carry the maximum amount of load. A continuous fibre
equal to the critical length the tensile strength would be around half
that of a continuous fibre which exceeds the critical length by 15
times. If the length of the fibre is smaller than the critical length, the
fibre wont manage to reach the tensile strength. The load carrying
capability of the composite will be very limited.
commonly used are the polyester resins. These are cheap and have
a good adhesion to the glass fibres. Epoxies are somewhat of better
properties than polyester, are much more expensive. The Polyimides
have a high temperature resistance and are also fire resistant. Even
higher performance polymers include PEEK and PPS are highly
resistant to high temperatures.
Fibre materials are materials that have a high aspect ratio. The
fibres can be crystalline for example most metals or they can be
amorphous where the atoms are randomly oriented- example glass.
They can also have a combination of amorphous and crystalline and
by changing the amount of crystalline and amorphous a very big
change in properties: strength and stiffness can result.
Whiskers are materials, which have a very high length to diameter
ratio, the diameters can be submicron in size. They are single
crystals and very small therefore they have a very high degree of
crystalline perfection, the grain boundary will contain a mismatch of
grains, no amorphous regions. They are flaw free. Any flaw in the
material can act as a stress concentrator. They include a variety of
materials such as Alumina and Silicon Carbide. These materials are
very expensive and therefore are not as used as the fibre
composites.
Wires also have a very high length to diameter ratio. Are used quite
a lot for example in the production of car tyres, hydrogen hoses.
These wires are produced from a variety of high strength materials.
GFRP- glass fibres can be produced quite easily. The idea of adding
other oxides to Silica is to reduce the melting temperature of the
glass making it cheaper and easier to produce. Very fine glass fibres
made from E glass are very cheap but it can operate up to lower
temperatures since it can easily creep and soften. A composite,
which has to resist high temperatures glass fibres need to consist of
almost pure Silica. Advantages of glass fibres are easily to produce
and very versatile and the raw material is available. They are
chemically resistant, they are coated to avoid moisture.
Disadvantages include low stiffness and low rigidity; they can be
prone to osmotic degradation. Applications include the marine
industry, storage containers and industrial floorings. They can be
found in various forms, having a low modulus allows them to be
form in various forms. Can be woven, stitched, loose and joined
together to form a yard.
CFRP the techniques to produce carbon fibres are more expensive
than the techniques to form glass fibres. The higher the temperature
the higher the crystallinity and the fibre are more expensive. Carbon
fibres are very commonly coated with epoxy. The modulus of these
fibres is very higher. The higher the treatment temp the higher the
forms and starts propagating, the whiskers can bridge the crack and
thus hindering the crack propagation.