LECTURE 15:
COMPOSITE MATERIALS
By: Casey Keulen
COMPOSITES
-Composite materials are engineered materials made from two or more constituent materials that remain separate and distinct while forming a single component -Generally, one material forms a continuous matrix while the other provides the reinforcement - The two materials must be chemically inert with respect to each other so no interaction occurs upon heating until one of the components melts, an exception to this condition is a small degree of interdiffusion at the reinforcement-matrix interface to increase bonding
COMPOSITES
COMPOSITES
Composites can be found in:
-Boat hulls -The aerospace industry (structural components as well as engines and motors) -Automotive parts (panels, frames, dashboards, body repairs) -Sinks, bathtubs, hot tubs, swimming pools -Cement buildings, bridges -Surfboards, snowboards, skis -Golf clubs, fishing poles, hockey sticks -Trees are technically composite materials, plywood -Electrical boxes, circuit boards, contacts -Everywhere
COMPOSITES
Composites can be classified by their matrix material which include:
-Metal matrix composites (MMCs) -Ceramic matrix composites (CMCs)
-Polymer matrix composites (PMCs) or sometimes referred to as organic matrix composites (OMCs)
COMPOSITES
MMC - Metal Matrix Composites
-The matrix is relatively soft and flexible. -The reinforcement must have high strength and stiffness -Since the load must be transferred from the matrix to the reinforcement, the reinforcement-matrix bond must be strong. MMC use: -Two types of particulates ( dispersion strengthened alloys and regular particulate composites) -Or long fiber reinforcements
COMPOSITES
PMC - Polymer Matrix Composites
-The matrix is relatively soft and flexible -The reinforcement must have high strength and stiffness -Since the load must be transferred from matrix to reinforcement, the reinforcement-matrix bond must be strong
SAPs are produced using different methods, two examples are as follows: -Al and Al2O3 powders are blended then compacted at high pressure then sintered like a ceramic. -Al powder is heated in air to form a thick film of Al2O3 on each particle, when the powder is compacted the Al2O3 film fractures into tiny particles and becomes surrounded by the Al during sintering
Properties of SAP compared to 2024-T8, 7075-T6 and a boron fiber strengthened 1100 alloy.
THORIA-DISPERSED COMPOSTIES
-An important group of dispersion-strengthened composites is thoria-dispersed (TD) metals -Thorium is an element on the periodic table (atomic number 90) -A common example is TD-nickel
TD-nickel composites roduced by: -Powders of metallic Th and Ni are ball milled, compacted at high pressure and then sintered. -The compact is then heated in air and oxygen diffuses in to react with Th metal to form a fine dispersion of ThO2. -This method, internal oxidation is also Electron micrograph of TD-Ni with 300 used for fabricating the W-ThO2 nm diameter ThO2 particles (X2000) composites.
-Electrical contacts used in switches, relays and motors must be quite wear resistant to stand up in service -Highly conductive metals such as Cu and Ag are relatively soft and thus show excessive wear when used as contacts resulting in arcing and poor electrical conduction. -The goal is to produce a contact that is both a good conductor and has excellent wear properties -This is done by using silver reinforced with tungsten particles, the Ag is a terrific conductor while the W provides good wear properties
RULE OF MIXTURES
For particulate composites, the rule of mixtures predicts the density of the composite as well as other properties (although other properties may vary depending on how the dispersed phase is arranged) Density, r, is given as a fraction, f, as:
rc f m rm f f r f
Note that f m 1 f f
RULE OF MIXTURES
For fiber reinforced composites, the rule of mixtures predicts the density of the composite as well as electrical and thermal conductivity along the direction of the fibers if they are continuous and unidirectional. Density, r, is given as a fraction, f, as:
rc f m rm f f r f
For thermal conductivity:
Note that f m 1 f f
For electrical conductivity:
Kc fm Km f f K f
c f m m f f f
Thermal and electrical energy can be transferred through the composite at a rate that is proportional to the volume fraction, f of the conductive material
RULE OF MIXTURES
In a composite material with a metal matrix and ceramic fibers, the bulk of the energy would be transferred through the matrix. In a composite consisting of a polymer matrix containing metallic fibers, the energy would be transferred through the fibers. When the fibers are not continuous or unidirectional, the simple rule of mixtures may not apply. For example, in a metal fiber-polymer matrix composite, electrical conductivity would be low and would depend on the length of the fibers, the volume fraction of fibers and how often the fibers touch one another.
RULE OF MIXTURES
The rule of mixtures can also be used to predict the modulus of elasticity when the fibers are continuous and unidirectional. Parallel to the fibers, the modulus of elasticity may be as high as:
Ec f m E m f f E f
However, when the applied load is very large, the matrix begins to deform and the stress-strain curve is no longer linear. Since the matrix now contributes little to the stiffness, the modulus is approximated by:
Ec f f E f
RULE OF MIXTURES
Perpendicular to the fibers, the modulus of elasticity may be as high as:
ff f 1 m Ec E f Em
There are many good examples provided in your text by Askland and Phule in the chapter, Composites: Teamwork and Synergy in Materials. Review this chapter and the examples provided.
FIBER ORIENTATION
-Maximum strength is obtained when long fibers are oriented parallel to the applied load -The effect of fiber orientation and strength can be seen in the plot
FIBER ORIENTATION
-The properties of fiber composites can be tailored to meet different loading requirements -By using combinations of different fiber orientation quasi-isotropic materials may be produced
Figure (a) shows a unidirectional arrangement Figure (b) shows a quasi-isotropic arrangement
FIBER ORIENTATION
-A three dimensional weave is also possible -This could be found when fabrics are knitted or weaved together
FIBER PROPERTIES
In most fiber-reinforced composites, the fibers are strong, stiff and lightweight. If the composite is to used at elevated temperatures, the fiber should also have a high melting temperature. The specific strength and specific modulus of fibers are important characteristics given by:
Specific Strength TS
Specific modulus
Where TS is the tensile strength, E is the elastic modulus and r is the density.
FIBER PROPERTIES
-On the left is a graph showing specific strength vs. specific modulus for different types of fibers
TYPES OF FIBERS
Some commonly used fibers for polymer matrix composites: -Glass fibers -Carbon fibers -Aramid fibers Some commonly used fibers for metal matrix composites: -Boron fibers -Carbon fibers -Oxide ceramic and non-oxide ceramic fibers
GLASS FIBERS
-Due to the relatively inexpensive cost glass fibers are the most commonly used reinforcement -There are a variety of types of glass, they are all compounds of silica with a variety of metallic oxides
Designation: E, electrical Property or Characteristic: low electrical conductivity
S, strength
C, chemical
high strength
high chemical durability
M, modulus
A, alkali D, dielectric
high stiffness
high alkali or soda lime glass low dielectric constant
-The most commonly used glass is E-glass, this is the most popular because of its cost
CARBON FIBERS
-Carbon fibers have gained a lot of popularity in the last two decades due to the price reduction
Carbon fiber composites are five times stronger than 1020 steel yet five times lighter. In comparison to 6061 aluminum, carbon fiber composites are seven times stronger and two times stiffer yet still 1.5 times lighter -Initially used exclusively by the aerospace industry they are becoming more and more common in fields such as automotive, civil infrastructure, and paper production
ARAMID FIBERS
-Aramid fibers are also becoming more and more common -They have the highest level of specific strength of all the common fibers -They are commonly used when a degree of impact resistance is required such as in ballistic armour -The most common type of aramid is Kevlar
-Chopped strand mat: assembled from chopped filaments bound with a binder
-Continuous filament random mat: assembled from continuous filaments bound with a binder -Many varieties of woven fabrics: woven from rovings
MATRIX MATERIALS
-Examples: oxygen bottles for firemen, rocket motors, tennis rackets, shafts
Researcher from Aerospace Manufacturing Technology Center in Montreal molding members for a helicopter
THE END
ANY QUESTIONS?