GROUP 7: COMPOSITES
laminates, sandwiches, and others.
Composite made up of various parts or elements
Composite material is a material made from two or more constituent
materials with significantly different physical or chemical properties that, when
combined, produce a material with characteristics different from the individual
components.
Is a nonuniform solid consisting of two or more different materials that
are mechanically or metallurgically bonded together
Properties of composite materials:
Stiffness
Strength
Weight
High-temperature performance
Corrosion resistance
Hardness
Conductivity
These properties are not possible with the individual components by
themselves. Analysis of these properties shows that they depend on:
1. The properties of the individual components
2. The relative amounts of the components
3. The size, shape, and distribution of the discontinuous components
4. The orientation of the various components
5. The degree of bonding between the components
Two components of Composites:
1. Matrix surrounds and supports the reinforcement materials
Good shear properties
Low density
2. Reinforcement impart their special mechanical and physical
properties to enhance the matrix properties
High strength
High stiffness
Low density
The earliest man-made composite materials were straw and mud combined to
form bricks for building and construction.
Concrete is the most common artificial composite material of all and typically
consists of loose stones (aggregate) held with a matrix of cement.
Fiberglass the first modern composite material. The matrix is plastic and the
reinforcement is glass that has been made into fine threads.
LAMINAR COMPOSITES
Laminar composites is a composite material that consists of two or more
layers of different materials that are bonded together in some manner and
include thin coatings, thicker protective surfaces, claddings, bimetallics,
These impart properties such as:
Reduced cost enhanced corrosion resistance or wear resistance
Electrical insulation or conductivity
Unique expansion characteristics
Lighter weight
Improved strength
Altered appearance
Laminar Composite Structure Types:
1. Conventional Laminar Structure consists of two or more layers that
are bonded together to form an integral piece
2. Sandwich Structure with a foam core has a thick core of low density
foam that is placed between thin, high-density surfaces
3. Honeycomb Sandwich Structure an alternative to foam core. This
produces lightweight, high-strength, high-rigidity composites
Applying Laminar Composites:
Plywood a laminated composite of thin layers of wood in which
successive layers have different grain or fiber orientations.
Safety glass a layer of polymeric adhesive is placed between two
pieces of glasses and serves to retain fragments when the glass is
broken
Aramid-aluminum laminates (Arall) consists of thin sheets of
aluminum bonded with woven adhesive-impregnated aramid fibers.
Laminated plastics a plastic material consisting of superimposed
layers of a synthetic resin-impregnated or resin-coated filler which have
been bonded together (usually by means of heat and pressure) to form
a single piece
Bimetallic strip is a laminate of two metals with significantly different
coefficients of thermal expansion
Sandwich material is a laminar structure composed of a thick, low-density
core placed between thin, high-density surfaces
PARTICULATE COMPOSITES
Particulate composites a composite that consists of tiny particles of one
material embedded in another material
Advantages:
Provide reinforcement to the matrix material
Improved material properties
Tailored material properties
Manufacturing flexibility
High creep resistance
High tensile strength at elevated temperatures
 High toughness Properties of fiber-reinforced composites depend strongly on several
High strength to weight ratio (low density high tensile strength) characteristics:
In which materials can particulate composite be used? The properties of the fiber material
Metal (Aluminum Alloy) The volume fraction of fibers
Polymer (Rubber) The aspect ratio of the fibers
Ceramics (Concrete) The orientation of the fibers
Dispersion-strengthened materials are particulate composites where a small The degree of bonding between the fiber and the matrix
amount of hard, brittle, small-sized particles (typically, oxides or carbides) are The properties of the matrix
dispersed throughout a softer, more ductile metal matrix
True particulate composites contain large amount of coarse particles and are Glass Fiber is one of the most common fibers in the composites industry
usually designed to produce some desired combination of properties rather The main reason for its use is the relatively low costs involved as glass
than increased strength. fiber is significantly cheaper than carbon fiber.
Isotropic uniform in all directions (the properties of particulate composites are This makes glass fiber attractive for the production of large composite
usually isotropic because of their unique geometry) structures (boats, wind turbines)
Glass fiber is available in various grades: The E-type borosilicate glass is
FIBER-REINFORCED COMPOSITES the most common one, but also R- and S-type are available. Both R and
Fiber-reinforced composite geometry the most popular type of composite S grades have better mechanical properties but are more expensive
material where continuous or discontinuous thin fibers of one material are compared to the E grade.
embedded in a matrix of another. Advantages:
Objective: Cost (relatively cheap)
Enhance strength Good chemical resistance to acids and solvents
Stiffness Electrically insulating
Fatigue Higher elongation at break compared to carbon fiber
Resistance High temperature resistance
Strength-to-weight ratio by incorporating strong, stiff, but possibly Low moisture absorption
brittle, fibers in a softer, more ductile matrix High strength to weight ratio
Some common geometries for fiber-reinforced composites: Heat resistance
Aligned Low dielectric constant
The properties of aligned fiber-reinforced composite materials are Disadvantages:
highly anisotropic. The longitudinal tensile strength will be high Not as strong as other materials
whereas the transverse tensile strength can be much less than even the Not as stiff as many materials such as carbon fiber
matrix tensile strength.
Two different geometries for aligned fibers: Carbon Fiber is a material consisting of fibers about 5-10 m in diameter and
1. Continuous & Aligned composed mostly of carbon atoms. The carbon atoms are bonded together in
2. Discontinuous & Aligned crystals that are aligned parallel to the long axis of the fiber.
Random Advantages:
This is also called discrete (or chopped) fibers. The strength will not be Lightweight structures
as high as with aligned fibers, however, the advantage is that the
Thermal expansion is basically zero
material will be isotropic and cheaper.
Resist very high temperature
Woven
Do not suffer fatigue issues
The fibers are woven into a fabric, which is layered with the matrix
Permeable to X-ray
material to make a laminated surface.
Does not corrode
Disadvantages:
Cost (Fairly expensive)
Electric conductor
Reflects radio waves
Part disintegrates when broken
More labor intensive
Ceramic Fiber
Ceramic fibers, metal wires, and specially grown whiskers have also
been used as reinforcing fibers for high-strength, high-temperature
applications.
Metal fibers can also be used to provide electrical conductivity or
shielding from electromagnetic interference to lightweight polymeric
matrix
With demand for less expensive, environmentally friendly materials,
the natural fibers have also assumed an engineering material role.
Cotton, hemp, flax, jute, coir (coconut husk), and sisal have found use
in various composites.
Thermoplastic fibers, such as nylon and polyester, have been used to
enhance the toughness and impact strength of the brittle thermoset
resins
Fiber Reinforce Composites In the Industry
Automotive
The automotive industry has adopted composites slowly due to their costs.
Particulate reinforced plastics have been used for some time but fiber
reinforced composites have only really been used in high end sports cars but are
starting to make their way into traditional vehicles. Racecars have used carbon
fiber materials for many years.
Aerospace
Carbon fiber composites are now quite common in commercial and military
aviation. The Boeing 787 and Airbus A350 XWB have roughly 50% of their
structure from composite materials. Carbon fiber materials are also common in
helicopter systems, rocket motors, satellite systems, and turbine engines.
Marine
Fiberglass has been the common material for recreational boats and yachts for
many years. These are not traditional laminated composites rather the glass
fibers are oriented randomly giving the structure more uniform material
properties. Being fairly cheap, glass fiber can be used in large structures;
whereas carbon fiber would be too expensive.
Sporting Goods
Golf clubs and tennis rackets have used carbon fiber for many years as it
provides lightweight and high stiffness.
Advanced Fiber-Reinforced Composites
Advanced Fiber Reinforced Composites are materials known due to their
applications requiring exceptional combinations of strength, stiffness and
lightweight. Their fiber content exceeds 50% by weight and for their great
modulus of plasticity.
Different properties required in developing these materials:
Superior Creep and Fatigue Resistance
Low Thermal Expansion
Low Friction and Wear
Vibration-damping characteristics
Environmental Stability
Four basic types of Advanced Fiber-Reinforced Composites:
The four basic types of advanced composites are developed by
matching the fiber and conditions of application
1. The advanced organic or resin matrix composites
The Resin Matrix Composites is the type of fiber-reinforced materials
wherein two types of fiber are combined into a single matrix. These
composites usually use high strength, high-modulus fibers of graphite,
aramid (Kevlar), or boron. The different properties can be put in
desired orientation at about one-half the weight of Aluminum or one-
sixth that of steel. These composites thermal expansion is designed to
be low or even negative. But they only have limited service of
temperature because polymer matrix loses strength when heated.
Common applications:
Sporting equipments
Armor plates
Low temperature aerospace components
2. Metal matrix composites
Metal matrix composites are the types of composite that is quite
expensive because of the following properties they obtain. Their
reinforcing fiber may either be continuous or discontinuous that is
made up of 10% and 60% of the composite volume. Compared to resin
matrix composites metal matrix has the ability to withstand
temperature up to 1250C or 2300F. They offer higher stiffness and
strength especially at areas with elevated temperatures; better
elevated temperature properties and enhanced resistance to fatigue,
abrasion and wear. They are non-flammable, they do not absorb water
or gases and they are corrosion resistant to fuels and solvents.
Common applications:
Designs to have nonzero thermal expansion in the fiber
direction
Used in automotive connecting rods
 Automotive drive shafts, aircraft wing panel (offers significant
weight saving)
Turbine blades
3. Carbon-carbon composites
Carbon-carbon composites are the types of composites that actually
get stronger when heated. They could offer the possibility of a heat
resistant material that could operate at temperature above 2000C or
3600F, along with a strength that is 20 times that of conventional
graphite. However for temperatures over 540C, these composites
require coating to protect it from oxidizing (the coating may depend on
the different temperature ranges ). Their other properties include good
toughness, good thermal and electric conductivity, resistance to
corrosion and abrasion.
Current applications:
Nose cone of the space shuttle
Aircraft or racing car disc brakes
Automotive clutches
Aerospace turbines
4. Ceramic-matrix composites
Ceramic matrix composites provide high temperature resistance. They
offer light weight and good dimensional and environmental stability.
Fibers add directional strength, increases the fracture of toughness and
can be incorporated with unwoven, woven, knitted and braided forms.
Commonly used reinforcements are carbon fiber, glass fiber, fibers of
various matrix materials and ceramic whiskers.
Glass matrices can operate at temperatures 1500C or 2700F while
crystalline ceramics based on alumina, silicon carbide, boron nitride,
titanium diboride, or zirconia can be used at even higher temperatures.
Ceramic-ceramic composites are most likely very expensive. That is
why their applications are limited because its advantages or benefits
are quite appealing.
Common application:
Gas turbine components
High-pressure heat exchangers
High temperature filters
Reduce weight
Improve fatigue and fracture resistance
Types of Hybrid Composites:
Interply also known as tow-by-tow; it is the alternating layers of
fibers and contains two or more different composite systems
Intraply it consists of two or more different fibers mixed in the same
ply
Interply-Intraply it consists of two or more different fibers in the
same ply and specific composite systems in more than one ply
Selected Placement this uses a costly material of combination of
fibers only where it is needed
Interply Knitting a fiber is being vertically interplied stitched with
another type of fiber that strengthens the composite
Design and Fabrication
The design of composite materials involves:
Selection of the component materials
Knowing the right amount of each component
Knowing the size, shape, distribution, and orientation of the
components
Selection of an appropriate fabrication method (many fabrication
methods have been specifically developed for use with composite
materials)
Bulk-molding compounds can be shaped and cured by: compression, transfer,
and injection molding to produce three-dimensional fiber-reinforced products
for numerous applications.
Sheet-molding compounds are press formed resulting to a light-weight and
corrosion-resistant products.

Hybrid Composites
Hybrid composites are combinations of two or more different types of fibers
in a common matrix.
Purpose:
Balance strength and stiffness
Stabilized dimensions
Reduce cost