Introduction
There is an unabated quest for new materials which will satisfy the specific
requirements for various applications like structural, medical, house-hold, industrial,
construction, transportation, electrical; electronics, etc. Metals are the most
commonly used materials in these applications. In the yore of time, there have been
specific requirements on the properties of these materials. It is impossible of any
material to fulfill all these properties. Hence, newer materials are developed. In the
course, we are going to learn more about composite materials. First, we will deal
with primary understanding of these materials and then we will learn the mechanics
of these materials.
In the following lectures, we will introduce the composite materials, their evolution;
constituents; fabrication; application; properties; forms, advantages-disadvantages
etc. In the present lecture we will introduce the composite materials with a formal
definition, need for these materials, their constituents and forms of constituents.
The composite materials can be natural or artificially made materials. In the following
section we will see the examples of these materials.
Why we need these materials?
There is unabated thirst for new materials with improved desired properties. All the
desired properties are difficult to find in a single material. For example, a material
which needs high fatigue life may not be cost effective. The list of the desired
properties, depending upon the requirement of the application, is given below.
1. Strength
2. Stiffness
3. Toughness
4. High corrosion resistance
5. High wear resistance
6. High chemical resistance
7. High environmental degradation resistance
8. Reduced weight
9. High fatigue life
10. Thermal insulation or conductivity
11. Electrical insulation or conductivity
12. Acoustic insulation
13. Radar transparency
14. Energy dissipation
15. Reduced cost
16. Attractiveness
The list of desired properties is in-exhaustive. It should be noted that the most
important characteristics of composite materials is that their properties
are tailorable, that is, one can design the required properties.
The existence of composite is not new. The word “composite” has become very
popular in recent four-five decades due to the use of modern composite materials in
various applications. The composites have existed from 10000 BC. For example, one
can see the article by Ashby [1]. The evolution of materials and their relative
importance over the years have been depicted in Figure 1 of this article. The common
composite was straw bricks, used as construction material.
Then the next composite material can be seen from Egypt around 4000 BC where
fibrous composite materials were used for preparing the writing material. These were
the laminated writing materials fabricated from the papyrus plant. Further, Egyptians
made containers from coarse fibres that were drawn from heat softened glass.
One more important application of composites can be seen around 1200 BC from
Mongols. Mongols invented the so called “modern” composite bow. The history shows
that the earliest proof of existence of composite bows dates back to 3000 BC - as
predicted by Angara Dating. The bow used various materials like wood, horn, sinew
(tendon), leather, bamboo and antler. The horn and antler were used to make the
main body of the bow as it is very flexible and resilient. Sinews were used to join and
cover the horn and antler together. Glue was prepared from the bladder of fish which
is used to glue all the things in place. The string of the bow was made from sinew,
horse hair and silk. The composite bow so prepared used to take almost a year for
fabrication. The bows were so powerful that one could shoot the arrows almost 1.5
km away. Until the discovery of gun-powder the composite bow used to be a very
lethal weapon as it was a short and handy weapon.
As said, “Need is the mother of all inventions”, the modern composites, that is,
polymer composites came into existence during the Second World War. During the
Second World War due to constraint impositions on various nations for crossing
boundaries as well as importing and exporting the materials, there was scarcity of
materials, especially in the military applications. During this period the fighter planes
were the most advanced instruments of war. The light weight yet strong materials
were in high demand. Further, applications like housing of electronic radar
equipments require non-metallic materials. Hence, the Glass Fibre Reinforced
Plastics (GFRP) were first used in these applications. Phenolic resins were used as
the matrix material. The first use of composite laminates can be seen in the Havilland
Mosquito Bomber of the British Royal Air Force.
The composites exist in day to day life applications as well. The most common
existence is in the form of concrete. Concrete is a composite made from gravel, sand
and cement. Further, when it is used along with steel to form structural components in
construction, it forms one further form of composite. The other material is wood which
is a composite made from cellulose and lignin. The advanced forms of wood
composites can be ply-woods. These can be particle bonded composites or mixture
of wooden planks/blocks with some binding agent. Now days, these are widely used
to make furniture and as construction materials.
The other examples include: wings of a bird, fins of a fish, trees and grass. A leaf of a
tree is also an excellent example of composite structure. The veins in the leaf not only
transport food and water, but also impart the strength to the leaf so that the leaf
remains stretched with maximum surface area. This helps the plant to extract more
energy from sun during photo-synthesis.
In a composite, typically, there are two constituents. One of the constituent acts as a
reinforcement and other acts as a matrix. Sometimes, the constituents are also
referred as phases.
Fibre: Fibre is an individual filament of the material. A filament with length to diameter
ratio above 1000 is called a fibre. The fibrous form of the reinforcement is widely
used. The fibres can be in the following two forms:
In the fibre reinforced composites, the fibre is the major load carrying
constituent.
2. Particulate: The reinforcement is in the form of particles which are of the order
of a few microns in diameter. The particles are generally added to increase the
modulus and decrease the ductility of the matrix materials. In this case, the
load is shared by both particles and matrix materials. However, the load
shared by the particles is much larger than the matrix material. For example, in
an automobile application carbon black (as a particulate reinforcement) is
added in rubber (as matrix material). The composite with reinforcement in
particle form is called a particulate composite.
3. Flake: Flake is a small, flat, thin piece or layer (or a chip) that is broken from a
larger piece. Since these are two dimensional in geometry, they impart almost
equal strength in all directions of their planes. Thus, these are very effective
reinforcement components. The flakes can be packed more densely when they
are laid parallel, even denser than unidirectional fibres and spheres. For
example, aluminum flakes are used in paints. They align themselves parallel to
the surface of the coating which imparts the good properties.
4. Whiskers: These are nearly perfect single crystal fibres. These are short,
discontinuous and polygonal in cross-section.
There are various reasons because of which the reinforcement is made in thin fibre
form. These reasons are given below.
The same fact has been explored in the composites with reinforcement in fibre form. As
the fibres are made of thin diameter, the inherent flaws in the material decrease. Hence,
the strength of the fibre increases as the fibre diameter decreases. This kind of
experimental study has revealed the similar results [2, 3]. This has been shown in
Figure 1.5 qualitatively.
b) The quality of load transfer between fibre and matrix depends upon the surface area
between fibre and matrix. If the surface area between fibre and matrix is more, better is
the load transfer. It can be shown that for given volume of fibres in a composite, the
surface area between fibre and matrix increases if the fibre diameter decreases.
Let be the average diameter of the fibres, be the length of the fibres and be the
number of fibres for a given volume of fibres in a composite. Then the surface area
available for load transfer is
(1.1)
(1.2)
Now, let us replace the fibres with a smaller average diameter of such that the volume
of the fibres is unchanged. Then the number of fibres required to maintain the same
fibre volume is
(1.3)
Thus, for a given volume of fibres in a composite, the area between fibre and matrix is
inversely proportional to the average diameter of the fibres.
c) The fibres should be flexible so that they can be bent easily without breaking. This
property of the fibres is very important for woven composites. In woven composites the
flexibility of fibres plays an important role. Ultra thin composites are used in deployable
structures.
The flexibility is simply the inverse of the bending stiffness. From mechanics of solids
study the bending stiffness is EI, where is Young’s modulus of the material and is
the second moment of area of the cross section of the fibre. For a cylindrical fibre, the
second moment of area is
(1.5)
Thus,
Flexibility (1.6)
Thus, from the above equation it is clear that if a fibre is thin, i.e. small in diameter, it is
more flexible.
Lecture 2: Reinforcement: Materials and Forms
The fibres that are used in the fabrication of a composite can be divided into two
broad categories as follows:
B. Advanced fibres
A. Natural fibres
The natural fibres are divided into following three sub categories.
o Animal fibers: silk, wool, spider silk, sinew, camel hair, etc.
o Plant/vegetable fibers: cotton (seed), jute (stem), hemp (stem), sisal
(leaf), ramie, bamboo, maize, sugarcane, banana, kapok, coir, abaca,
kenaf, flax, raffia palm, etc.
o Mineral fibers: asbestos, basalt, mineral wool, glass wool.
An advanced fibre is defined as a fibre which has a high specific stiffness (that is,
ratio of Young’s modulus to the density of the material, ) and a high specific
strength (that is the ratio of ultimate strength to the density of the material, ).
The fibres made from following materials are the advanced fibres.
Figure 1.6 shows the periodic table. The conventional metals are shown in yellow
colour whereas the materials of the advanced fibres are shown in blue colour. It can
be seen that the materials of the advanced fibres are lighter than the conventional
metals. These materials occupy higher position as compared to metals in the
periodic table. Thus, one can easily deduce that, in general, these materials have
higher specific properties (property per unit weight) than that of metals.
Boron Fiber
This fibre was first introduced by Talley in 1959 [15]. In commercial production of
boron fibres, the method of Chemical Vapour Deposition (CVD) is used. The CVD is a
process in which one material is deposited onto a substrate to produce near
theoretical density and small grain size for the deposited material. In CVD the
material is deposited on a thin filament. The material grows on this substrate and
produces a thicker filament. The size of the final filament is such that it could not be
produced by drawing or other conventional methods of producing fibres. It is the fine
and dense structure of the deposited material which determines the strength and
modulus of the fibre.
In the fabrication of boron fibre by CVD, the boron trichloride is mixed with hydrogen
and boron is deposited according to the reaction
In the process, the passage takes place for couple of minutes. During this process,
the atoms diffuse into tungsten core to produce the complete boridization and the
production of and . In the beginning the tungsten fibre of 12 diameter
is used, which increases to 12 . This step induces significant residual stresses in
the fibre. The core is subjected to compression and the neighbouring boron mantle is
subjected to tension.
Carbon Fiber:
The first carbon fibre for commercial use was fabricated by Thomas Edison.
Sixth lightest element and carbon - carbon covalent bond is the strongest in
nature.
Edison made carbon fiber from bamboo fibers.
Bamboo fiber is made up of cellulose.
Precursor fiber is carbonized rather than melting.
Filaments are made by controlled pyrolysis (chemical deposition by heat) of a
precursor material in fiber form by heat treatment at temperature of 1000-
3000
The carbon content in carbon fibers is about 80-90 % and in Graphite fibers the
carbon content is in excess of 99%. Carbon fibre is produced at about 1300
while the graphite fibre is produced in excess of 1900 .
The carbon fibers become graphitized by heat treatment at temperature above
1800 .
“Carbon fibers” term is used for both carbon fibers and graphite fibers.
Different fibers have different morphology, origin, size and shape.
The size of individual filament ranges from 3 to 147 .
Maximum use of temperature of the fibers ranges from 250 to 2000 .
The use temperature of a composite is controlled by the use temperature of the
matrix.
Precursor materials: There are two types of precursor materials (i)
Polyacrylonitrile (PAN) and (ii) rayon pitch, that is, the residue of petroleum
refining.
Fiber properties vary with varying temperature.
Fiber diameter ranges from 4 to10 .
A tow consists of about 3000 to 30000 filaments.
Small diameter results in very flexible fiber and can actually be tied in to a knot
without breaking the fiber.
Modulus and strength is controlled by the process. The procedure involves the
thermal decomposition of the organic precursor under well controlled conditions
of temperature and stress.
Cross section of fiber is non-circular, in general, it is kidney bean shape.
Heterogeneous microstructure consisting of numerous lamellar ribbons.
Morphology is very dependent on the manufacturing process.
PAN based carbon fibers typically have an onion skin appearance with the basal
planes in more or less circular arcs, whereas the morphology of pitch-based fiber
is such that the basal planes lie along radial planes. Thus, carbon fibers are
anisotropic.
Glass Fibre
What are the different types of glass fibres? What are their key features?
The types of glass fibres and their key features are as follows:
In this lecture we are going see some more advanced fibres. Further, we will see their
key features, applications and fabrication processes.
Alumina Fibre
These are ceramics fabricated by spinning a slurry mix of alumina particles and
additives to form a yarn which is then subjected to controlled heating.
Fibers retain strength at high temperature.
It also shows good electrical insulation at high temperatures.
It has good wear resistance and high hardness.
The upper continuous use temperature is about 1700 .
Fibers of glass, carbon and alumina are supplied in the form of tows (also called
rovings or strands) consisting of many individual continuous fiber filaments.
Du Pont has developed a commercial grade alumina fibre, known as Alumina FP
(polycrystalline alumina) fibre. Alumina FP fibres are compatible with both metal
and resin matrices. These fibres have a very high melting point of 2100 . They
can withstand temperatures up to 1000 without any loss of strength and
stiffness properties at this elevated temperature. They exhibit high compressive
strengths, when they are set in a matrix.
The Alumina whiskers are available and they exhibit excellent properties.
Alumina whiskers can have the tensile strength of 20700 MPa and the tensile
modulus of 427 GPa.
The Alumina has a unique combination of low thermal expansion, high thermal
conductivity and high compressive strength. The combination of these properties
gives good thermal shock resistance. These properties make Alumina suitable
for applications in furnace use as crucibles, tubes and thermocouple sheaths.
The good wear resistance and high hardness properties are harnessed in making
the components such as ball valves, piston pumps and deep drawing tools.
Aramid Fibre
These fibres are from Aromatic polyamide, that is, nylons family.
Aramid is derived from “Ar” of Aromatric and “amid” of polyamide.
Examples of fibres from nylon family: Polyamide 6, that is, nylon 6 and
Polyamide 6.6, that is, nylon 6.6
These are organic fibers.
Melt-spun from a liquid solution.
Du Pont developed these fibers under the trade name Kevlar. From poly (p-
phenylene terephthalamide (PPTA) polymer.
Morphology – radially arranged crystalline sheets resulting into anisotropic
properties.
Filament diameter about 12 and partially flexible.
High tensile strength.
Intermediate modulus.
Significantly lower strength in compression.
5 grades of Kevlar with varying engineering properties are available. Kevlar-29,
Kevlar-49, Kevlar-100, Kevlar-119 and Kevlar-129.
Silicon carbide fibres are ceramic fibers. These fibres are produced in similar fashion as
boron fibres are produced. The fibres are produced by two methods as follows:
The CVD with as the reactant, SiC is deposited on the core as follows:
These fibres are used to form fibrous products such as high temperature insulation,
filters, etc. These fibres have high resistance to chemical attack. Hence, these can be
used in harsh environments.
These are also used as a reinforcement in plastic, ceramic and metal matrix
composites.
Fiber Properties
The following are the important points regarding the fibre properties.
Density, axial modulus, axial Poisson’s ratio, axial tensile strength and coefficient
of thermal expansion are some of the important properties.
Advanced fibers exhibit a broad range of properties.
Properties of carbon fiber can vary significantly depending upon fabrication
process.
For the advanced fibres studied above one can attain either high modulus (>
700 GPa) or high strength (> 5 GPa) but not both attainable simultaneously.
SCS-6, IM8, boron and sapphire fibers offer the best combination of stiffness
and strength but have large diameters and thus limited flexibility. However, IM8
fibers are exception for flexibility.
The specific stiffness of some of these fibres is almost 13 times of structural
metals.
Similarly, the specific strength of some of these fibres is almost 16 times of
structural metals.
Weight saving, when the composites of these fibres are used, is tremendous due
to high specific stiffness and strength.
Actual properties of composite (fiber + matrix) are reduced.
Specific properties are reduced even further when the loading is in a direction
other than the length direction of fibers.
Tailorable properties.
One can get the desired heat transfer or electrical conductivity with proper
designing.
The increased fatigue resistance is attainable with the use of these fibre
composites.
Aging effect can be significantly lowered.
Note: The fibres are classified based on their values of modulus as follows:
In the previous lecture we have introduced various advanced fibres along with their
fabrication processes, precursor materials and key features. In the present lecture we
will introduce some matrix materials, their key features and applications.
The matrix materials used in composites can be broadly categorized as: Polymers,
Metals, Ceramics and Carbon and Graphite.
1. Thermoplastic – which soften upon heating and can be reshaped with heat and
pressure.
2. Thermoset – which become cross linked during fabrication and does not soften
upon reheating.
1. polypropylene,
2. polyvinyl chloride,
3. nylon,
4. polyurethane,
5. poly-ether-ether ketone (PEEK),
6. polyphenylene sulfide (PPS),
7. polysulpone.
1. higher toughness
2. high volume
3. low cost processing
4. The use temperature range is upto 225 .
What are the thermoset matrix materials? What are their key features?
1. polyesters,
2. epoxies,
3. polyimides
The key features of these materials are given for individual material in the following.
Polyesters
Epoxy
1. Expensive
2. Better moisture resistance
3. Lower shrinkage on curing
4. Use temperature is about 175
Polyimide
What are the problems with the use of polymer matrix materials?
The comparison between the thermoplastic and thermoset matrix materials is given
in Table 1 below:
Thermoplastics Thermosets
Soften upon heat and pressure Decompose upon heating
Hence, can be repaired Difficult to repair
Low strains are required
High strains are required for failure
for failure
Can be re-processed Can not be re-processed
Indefinite shelf life Limited shelf life
Short curing cycles Long curing cycles
Tacky and therefore,
Non tacky and easy to handle
difficult to handle
Excellent resistance to solvents Fair resistance to solvents
Higher processing temperature is
Lower processing
required. Hence, viscosities make the
temperature is required.
processing difficult.
What are the common metals used as matrix materials? What are their
advantages and disadvantages?
The common metals used as matrix materials are aluminum, titanium and copper.
Advantages:
Dis-advantages:
1. Heavier
2. More susceptible to interface degradation at the fiber/matrix interface and
3. Corrosion is a major problem for the metals
What are the ceramic matrix materials? What are their advantages and
disadvantages?
The carbon, silicon carbide and silicon nitride are ceramics and used as matrix
materials.
Ceramic:
1. The ceramic composites have very high temperature range of above 2000 .
2. High elastic modulus
3. Low density
Figure 1.12 depicts the range of use temperature for matrix material in composites. It
should be noted that for the structural applications the maximum use temperature is a
critical parameter. This maximum temperature depends upon the maximum use
temperature of the matrix materials.
Figure 1.12: Range of use temperature for matrix materials in
composites
1. Unidirectional lamina:
o It is basic form of continuous fiber composites.
o A lamina is also called by ply or layer.
o Fibers are in same direction.
o Orthotropic in nature with different properties in principal material
directions.
o For sufficient number of filaments (or layers) in the thickness direction, the
effective properties in the transverse plane (perpendicular to the fibers)
may be isotropic. Such a composite is called as transversely isotropic.
2. Woven fabrics:
o Examples of woven fabric are clothes, baskets, hats, etc.
o Flexible fibers such as glass, carbon, aramid can be woven in to cloth
fabric, can be impregnated with a matrix material.
o Different patterns of weaving are shown in Figure 1.13.
3. Laminate:
1. Stacking of unidirectional or woven fabric layers at different fiber
orientations.
2. Effective properties vary with:
1. orientation
2. thickness
3. stacking sequence
Hybrid composites:
The hybrid composite are composites in which two or more types of fibres are used.
Collectively, these are called as hybrids. The use of two or more fibres allows the
combination of desired properties from the fibres. For example, combination of aramid
and carbon fibres gives excellent tensile properties of aramid and compressive
properties of carbon fibers. Further, the aramid fibres are less expensive as compared
to carbon fibres.
There are various factors upon which the properties of the composite depend. Following
are the various factors:
1. Properties of the constituent materials. Apart from this, the properties of other
phases present, like additives, fillers and other reaction phases also affect the
properties of the composite.
2. Length of the fibre.
3. Orientation of the fibres (with respect to the loading direction).
4. Cross sectional shape of the fibre.
5. Distribution and arrangement of the fibres in the matrix material.
6. Proportions of the fibre and matrix material, that is, volume fractions of the
constituent materials.
Notation for Composite Designation:
The composites are designated by the combination of the fibre and matrix system. The
fibre and matrix materials are separated by a slash , that is, fibre material/matrix
material. Further, one needs to specify the volume fractions of the constituents. In
general, the fibre volume fraction is specified. For example: AS4/PEEK, , that
is, a carbon composite with AS4 fibres and PEEK as the matrix material with fibre
volume fraction of 45%. Other examples are: T300/5208, T700/M21, Kevlar/Epoxy,
Boron/Al, SCS-6/Ti-15-3, S2 Glass/Epoxy.
Introduction
In this lecture we are going to discuss some of the terms and their definitions that are
used in the composites. These terms will be frequently used in our course. We will
conclude this lecture with advantages and disadvantages of the composite materials.
The following are the useful terminologies used in the composite related studies.
The composite materials have high specific stiffness and strengths. Thus, these
material offer better properties at lesser weight as compared to conventional
materials. Due to this, one gets improved performance at reduced energy
consumption.
2. Tailorable design:
A large set of design parameters are available to choose from. Thus, making the
design procedure more versatile. The available design parameters are:
3. Fatigue Life:
The composites can with stand more number of fatigue cycles than that of
aluminum. The critical structural components in aircraft require high fatigue life.
The use of composites in fabrication of such structural components is thus
justified.
4. Dimensional Stability:
Strain due to temperature can change shape, size, increase friction, wear and
thermal stresses. The dimensional stability is very important in application like
space antenna. For composites, with proper design it is possible to achieve
almost zero coefficient of thermal expansion.
5. Corrosion Resistance:
Polymer and ceramic matrix material used to make composites have high
resistance to corrosion from moisture, chemicals.
The components fabricated from composite are cost effective with automated
methods like filament winding, pultrusion and tape laying. There is a lesser
wastage of the raw materials as the product is fabricated to the final product size
unlike in metals.
7. Conductivity:
The list of advantages of composite is quite long. One can find more on advantages of
composite in reference books and open literature.
Introduction
This lecture is dedicated to the use of composites. The use of composites is almost
ubiquitous! The use of composites is an inexhaustive list. In the following we cite
some important applications.
The applications of the composites are given in the following as per the area of
application.
Aerospace:
Missile:
Launch Vehicle:
Sports Equipments
Tennis rockets, golf clubs, base-ball bats, helmets, skis, hockey sticks, fishing
rods, boat hulls, wind surfing boards, water skis, sails, canoes and racing
shells, paddles, yachting rope, speed boat, scuba diving tanks, race cars
reduced weight, maintenance, corrosion resistance.
Automotive
Lower weight and greater durability, corrosion resistance, fatigue life, wear and
impact resistance.
Drive shafts, fan blades and shrouds, springs, bumpers, interior panels, tires,
brake shoes, clutch plates, gaskets, hoses, belts and engine parts.
Carbon and glass fiber composites pultruted over on aluminum cylinder to
create drive shaft.
Fuel saving –braking energy can be stored in to a carbon fiber super flywheels.
Other applications include: mirror housings, radiator end caps, air filter housing,
accelerating pedals, rear view mirrors, head-lamp housings, and intake
manifolds, fuel tanks.
Infrastructure Structures:
Industrial:
Drive,
conveyer belts,
hoses,
tear and puncture resistant fabrics,
rotor vanes,
mandrels,
ropes,
cables.
Medical:
Wheelchairs,
Crutches,
Hip joints,
Heat valves,
Dentistry,
Surgical equipments
Electronic:
Military:
Helmets,
bullet proof vests,
impact resistant vehicles,
lighter and less detectable ships,
portable bridges.
Marine:
Rotor blades including blade shell, integral webs, spars or box structure.
Mast
Generator housing