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Introduction to Advanced Materials (8 hours)
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2.1 Advanced Composite Materials
Introduction to Composite
Combination of two or more individual
materials
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Terminology/Classification
Composite:
-- Multiphase material that is artificially
made.
Phase types:
-- Matrix - is continuous
-- Dispersed/reinforcement - is discontinuous and
surrounded by matrix
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Terminology/Classification
Matrix phase:
-- Purposes are to: woven
- principal load carrying agent fibers
- transfer stress to dispersed phase
- support and protect dispersed
phase from environment
-- Types: MMC, CMC, PMC 0.5 mm
cross
metal ceramic polymer section
view
Dispersed phase:
-- Purpose:
MMC: increase sy, TS, creep resist. 0.5 mm
CMC: increase KIc Reprinted with permission from
D. Hull and T.W. Clyne, An
PMC: increase E, sy, TS, creep resist. Introduction to Composite Materials,
2nd ed., Cambridge University Press,
-- Types: particle, fiber, structural New York, 1996, Fig. 3.6, p. 47.
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Classification of Composites
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Classification: Particle-Reinforced (i)
Particle-reinforced Fiber-reinforced Structural
Examples:
- Spheroidite matrix: particles: Adapted from Fig.
cementite 10.19, Callister &
steel ferrite (a) Rethwisch 8e. (Fig.
(ductile) (Fe C) 10.19 is copyright
3 United States Steel
(brittle) Corporation, 1971.)
60 mm
Adapted from Fig.
- WC/Co matrix: particles: 16.4, Callister &
cemented cobalt WC Rethwisch 8e. (Fig.
16.4 is courtesy
(ductile, (brittle,
carbide tough)
: hard)
Carboloy Systems,
Department, General
Electric Company.)
600 mm
Adapted from Fig.
16.5, Callister &
- Automobile matrix: particles: Rethwisch 8e. (Fig.
tire rubber rubber carbon 16.5 is courtesy
Goodyear Tire and
(compliant) black Rubber Company.)
(stiff)
0.75 mm 8
Classification: Particle-Reinforced (ii)
Prestressed concrete
- Rebar/remesh placed under tension during setting of concrete
- Release of tension after setting places concrete in a state of compression
- To fracture concrete, applied tensile stress must exceed this
compressive stress
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0 20 4 0 6 0 8 0 10 0 vol% tungsten
(Cu) (W)
Application to other properties:
-- Electrical conductivity, se: Replace Es in equations with ses.
-- Thermal conductivity, k: Replace Es in equations with ks.
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Classification: Fiber-Reinforced (i)
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Classification: Fiber-Reinforced (ii)
Particle-reinforced Fiber-reinforced Structural
Fiber Types
Whiskers - thin single crystals - large length to diameter ratios
graphite, silicon nitride, silicon carbide
high crystal perfection extremely strong, strongest known
very expensive and difficult to disperse
Fibers
polycrystalline or amorphous
generally polymers or ceramics
Ex: alumina, aramid, E-glass, boron, UHMWPE
Wires
metals steel, molybdenum, tungsten
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Longitudinal
direction
Fiber Alignment
Adapted from Fig. 16.8,
Callister & Rethwisch 8e.
Transverse
direction
aligned
continuous aligned random
discontinuous 13
Classification: Fiber-Reinforced (iii)
(a) fracture
surface
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Classification: Fiber-Reinforced (v)
o It is a material consisting of several fibers and composed mostly of carbon atoms that bonded
together to form a long chain
o Each fiber is about 5 10 m thick in diameter. Carbon fiber is made from organic polymers.
o The crystal alignment gives the fiber high strength- to-volume ratio. Carbon fiber is actually 5
times stronger than steel. It is also 2 times more stiff. Carbon fibers are usually combined with
other materials to form a composite (such as carbon fiber reinforced plastic) to provide a high
strength to weight ratio material.
*Polyacrylonitrile is used as
the precursor for 90% of
carbon fiber production
The stiffness of a material is measured by its modulus of elasticity. The modulus of carbon
fiber is typically 20 msi (138 Gpa) and its ultimate tensile strength is typically 500 ksi (3.5
Gpa). High stiffness and strength carbon fiber materials are also available through
specialized heat treatment processes with much higher values.
Carbon fiber reinforced composites are very strong for their weight. They're often stronger
than steel, but a whole lot lighter. Because of this, they can be used to replace metals in many
uses, from parts for airplanes and the space shuttle to tennis rackets and golf clubs.
FUTURE OF CARBON FIBER
ALTERNATE ENERGY WIND TURBINES, COMPRESSED NATURAL GAS
STORAGE AND TRANSPORTATION, FUEL CELLS
FUEL EFFICIENT AUTOMOBILES CURRENTLY USED IN SMALL
PRODUCTION, HIGH PERFORMANCE AUTOMOBILES, BUT MOVING TOWARD
LARGE PRODUCTION SERIES CARS
Carbon fiber
composite QLite
compressed natural
gas (CNG) fuel Carbon fiber drill
storage tanks risers & tubulars
Source : Source :
www.kompozit.org.tr www.zoltek.com
2.2 Basic concepts and
physical properties
Mechanical Properties of the composites is strongly influenced by :
Volume fraction of fibre-matrix
Different micro & macro
Homogeneity of the mix
structure
Fibre alignment
150
0 20 4 0 6 0 8 0 10 0 vol% tungsten
(Cu) (W)
Application to other properties:
-- Electrical conductivity, se: Replace Es in equations with ses.
-- Thermal conductivity, k: Replace Es in equations with ks.
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Composite Stiffness: Longitudinal Loading
Continuous fibers - Estimate fiber-reinforced composite modulus of
elasticity for continuous fibers
Longitudinal deformation
sc = smVm + sfVf and c = m = f
c = composite
f = fiber
m = matrix
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Composite Stiffness: Transverse Loading
In transverse loading the fibers carry less of the load
c = composite
f = fiber
m = matrix
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Longitudinal vs transverse loading
https://www.princeton.edu/~maelabs/hpt/materials/mater_60.htm
Composite Stiffness
Particle-reinforced Fiber-reinforced Structural
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Composite Strength
Particle-reinforced Fiber-reinforced Structural
2l
2. When l < lc
s cd l c Vf s m (1Vf )
*
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Composite Production Methods (i)
Pultrusion
Continuous fibers pulled through resin tank to impregnate fibers with thermosetting
resin
Impregnated fibers pass through steel die that preforms to the desired shape
Preformed stock passes through a curing die that is
precision machined to impart final shape
heated to initiate curing of the resin matrix
resistance w/SiC
whiskers
10 -10
s(MPa)
20 30 50 100 200 39
Summary
Composites types are designated by:
-- the matrix material (CMC, MMC, PMC)
-- the reinforcement (particles, fibers, structural)
Composite property benefits:
-- MMC: enhanced E, s, creep performance
-- CMC: enhanced KIc
-- PMC: enhanced E/r, sy, TS/r
Particulate-reinforced:
-- Types: large-particle and dispersion-strengthened
-- Properties are isotropic
Fiber-reinforced:
-- Types: continuous (aligned)
discontinuous (aligned or random)
-- Properties can be isotropic or anisotropic
Structural:
-- Laminates and sandwich panels
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