W 01-02 ME6093 Intro

Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
ME 6093
Mechanics of
Composites
Fall 2015
Off ered By: Dr Rizwan Saeed Choudhry
Dr Rizwan Saeed Choudhry
NATIONAL
UNIVERSITY
OF
SCIENCES
&
TECHNOLOG
Y
BE (NUST, Pakistan - 2002)

MS (NUST, Pakistan - 2003)
MS (The Uni. of Manchester, UK - 2004),
PhD (The Uni. of Manchester, UK - 2009)
Post Doc (Manchester (2009)
Web:
Post Doc Cambridge , UK (2013)
www.cemecomposites.com
Assistant Professor (NUST Dec 2009 to 2015)
Email:
Current role: Associate
Professor
Department of Mechanical
Engineering
Mohammad Ali Jinnah University
Islamabad Campus
rizwan.choudhry@gmail.com
rizwan.saeed@jinnah.edu.pk
Profile: LinkedIn
ProfGradIMMM IOM, UK
Professional Engineer P.Eng.
PEC, Pak
2
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
About the Course

Course Learning Outcomes
To understand the different types of composite materials and their current and
future applications in engineering.
To understand the effect of choice of processing route / manufacturing strategy on
mechanical properties of composites
To design and analyze structures made of composites (mechanics of composites).
To familiarize students with advanced concepts of computer aided modeling and
simulation of failure and damage in composites (FRC).
To develop an understanding of differences of testing standards for mechanical
testing of composites as opposed to those of traditional materials.
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Books and References

Main Text books:
1. Introduction to Composite Materials Design, 2 nd Edition (2011) Ever J Barbero
2. An introduction to Composite Materials, 2nd edition By D. Hull & T. W. Clyne
Special Topics
3. Engineering Mechanics of Composites Materials 2 nd edition Isaac M Daniel, Ori Ishai
4. Material selection in mechanical design, 4 th edition, by M. F. Ashby
5. Principles of Composite Material Mechanics, 2 nd Edition by Ronald F. Gibson
All other sources consulted will be referred to in slides
A note about slides: The slides for lectures have been prepared using various sources.
For the lectures in first six weeks most of the slides are modified versions of Lecture
slides used by Professor Paul J Hogg at University of Manchester for the course
Composites Science and Engineering
4
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Lesson Plan
1. Introduction to Composites (constituent materials, forms and properties)
Week 1,2
Related reading: Chapter 2 Barbero, Chapter 1,2,3 Clyne + Lecture Slides
2. Manufacturing techniques for composites and process selection methodology
Week 3,4
Related reading: Chapter 3 Barbero, Chapter 11 Clyne, + relevant portions of chapter
5, 6 and 14 Ashby + Lecture Slides
3. Design for composites key considerations
Week 5
Related reading: Chapter 1 Barbero, Chapter 1,2,3 Clyne + Lecture Slides
4. Structure property relationship and micromechanics of composites
Week 6,7,8
Related reading: Chapter 4 Barbero, Chapter 4,5 Clyne + Lecture Slides
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Lesson Plan
5. Linear elastic stress analysis of composite structures (Macro-mechanics, ply-mechanics)
Week 9,10,11
Related reading: Chapter 5,6 Barbero, Chapter 5 Clyne + Lecture Slides
6. Mechanics of Short/discontinuous fiber reinforced composites (optional topic if time
permits)
Week 12
Related reading: Chapter 6 Gibson + Chapter 6 Clyne + Lecture Slides
7. Mechanical testing of composites and testing standards
Week 13,14
Related reading: Chapter 10 Daniel and Ishai + Lecture Slides
8. Failure theories for composites laminates and progressive damage modelling
Week 15,16
Related reading: Chapter 7,8 Barbero, Chapter 8,9 Clyne + Lecture Slides
9. Introduction to FE analysis of composites using ABAQUS (Optional topic if time permits)
6
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Structure
Credit Hours:
3-0
Contact Hours:
3-0
Final Exam:
40 - 50 %
Midterm:
20 - 30%
Quizzes:
10%
Assignments/Project:
20%
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Composite Materials - Basics

Composites are a heterogeneous combination of two or more materials
usually having distinct properties which remain distinct even after

forming the composite.
The performance and properties of the combination are designed to be
superior to those of constituents acting independently.
Adhesive or Mechanical bonding between the constituents
Filler material reinforces a weak matrix
Matrix low density ; Filler strong, stiff
Traditional examples : Wood, Bricks, Concrete
Advanced composite examples: Fibre reinforced plastics (FRP)
Carbon, Glass, Kevlar,
Natural fibre reinforced composites
Introduction What are composites?

Dictionary definition:
A composite refers to something
made up of various parts and
elements
The different constituents must have

two prime characteristics
Chemically different
Insoluble in each other.
In almost all cases, there is a

Strong and stiff component forming
the reinforcement
Soft constituent that binds the
reinforcement
Structural composites typically refer

to the Macrostructural level:
e.g. matrix, particles, fibres
9
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Types of composites
Classification on basis of matrix
Polymeric matrix composites
Metal Matrix composites
Ceramics matrix composites
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Classification of composites
The first level of classification of composites is by matrix type
The major composite classes are
Polymer Matrix Composites (PMCs)
Use a polymer-based material as the matrix, and a variety of fibres such as glass,
carbon and aramid as the reinforcement
PMCs are used in the greatest diversity of composite applications, as well as in

the largest quantities
They can be further classified into small groups according to the
Fibre e.g. glass, carbon or aramid composites
Matrix e.g. thermosetting, thermoplastic or rubber composites
They can also be categorised into short-fibre reinforced composites, or

continuous-fibre reinforced composites
Also known as FRP - Fibre Reinforced Polymers (or Plastics)
As these are the most common they will be the main focus of the course
11
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
(cont)
Metal Matrix Composites (MMCs)

Use a ductile metal such as aluminium for the matrix
Reinforced with fibres or particles of alumina, boron, silicon carbide
Increasingly found in the automotive industry
Ceramic Matrix Composites (CMCs)

Use a ceramic as the matrix and reinforce it with short fibres or whiskers such as
those made from silicon carbide and boron nitride
Used in very high temperature environments
12
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Types of composites
Classification on basis of reinforcements
Continuous fibre strands or roving

Chopped strands in short length
Chopped strand mat
Chopped strand aligned mat
Fibre Roving
Woven Fabrics 2D and 3D
made from roving or strands
Metal filament or wires
Solid or hollow microspheres
Robotic fibre placement at NCCEF,
Metal, glass or mica flakes
Single crystal whiskers of graphite, silicon carbide, copper etc. UK
Nano-particle and nano-fiber reinforcements
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
(cont)
The second level of classification is by reinforcement form

Fibre reinforcement
Fibre is characterised by a high aspect ratio, i.e. the length of the fibre is much
greater than its diameter
Fibres can be
Short i.e. where properties of composite vary with fibre length
Long or continuous, i.e. further increase in fibre length has no effect on the
composite properties. Long fibres typically have lengths comparable to that
of the final part. Long fibres are manufactured into preforms for ease of
manufacturing
These are the most common and will be discussed in detail later on
14
(cont)
Whisker reinforcement
Characterised by aspect ratios of approximately 20-100
Particulate reinforcement
Dimensions of particles are roughly equal. This category
includes
Spheres, rods, flakes etc.
Mostly tend to be included for cost reduction purposes and are
non-structural
Particulate and whisker reinforcements
are classified as discontinuous
reinforcements. This is especially so for
MMCs where the volume fractions of
particles is quite low
To provide a useful increase in properties, the reinforcement has to be

included at a sufficient volume fraction (typically >10%)
15
History of Composites
1940s
PMCs used to produce materials with
stiffnesses and strengths that were higher
than for the existing materials
Filament wound GRP rocket motors
Prototypes for aircraft applications
Structural alloys susceptible to corrosion

and creep damage
Gordon Aerolite Spitfire

Fuselage from flax-fibre composite
No property advantages & weight
same as aluminium fuselage
Al shortage never materialised,
concept dropped
16
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
1950s
Improved structural response and corrosion resistance of PMCs
Initial development of MMCs
Idea was to dramatically extend the structural efficiency of metallic materials
while retaining their advantages
1960s
Commercial applications for PMCs in sporting equipment
Improved design and production capabilities, and PMCs lower in costs
Development of Boron and SiC monofilaments
17
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
1970s
Cold war budgets allowed for significant research
in high-performance materials
Military aircraft built with composite sections
(tailskins & noncritical flight structures)
MMC piston
head liner
Energy crisis provided incentive for introduction of

PMCs into the manufacture of commercial aircraft
Development of carbon fibres
High cost of SiC whiskers led to development of
particulate reinforcements for MMCs
Nearly equivalent strengths & stiffness as whiskers
Reduced costs, eased processing
18
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
1980s
Development of monofilament reinforced Ti MMCs
Designed for high temperature aeronautical systems: blades for gas
turbine engines
Increased use of composites in military and commercial

aircraft
Commercial aircraft use composites for critical load-bearing
applications
Development of fibreglass structures for boats and marine

applications
19
Major applications of PMCs in the 80s

AV8B Harrier
all composite wing for improved
payload /range
27% of structural weight is composite
SAAB Grippen Wing
all composite
Airbus A320
all composite tail, up to
15% of structural weight
is composite
Starship Bizjet >75% of structural
weight was
composite.
Global Market had grown from about 1000 tonnes in 1980 to 5000 tonnes of fibres
in 1985 and almost 10,000 tonnes by 1989
20
Stealth
bomber
Specialist aircraft such as the B-2 stealth bomber mainly composite due to low
radar absorbance and ability to manufacture suitable shapes. 40% by weight
(60% by volume) composite
21
Re-vamping
earlier
aircraft
New tough composites used for bigger composite wings on F-18E/F

range up to 22% composite.
22
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
1990s
Development of MMCs for ground transportation, thermal management &
electronic packaging
This market is significantly larger than
the aerospace market
However market volumes are still very small
World market in 1999 was 2500tons

62% for ground
transportation
(automotive and rail)
23
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
2000s
Modern aircraft designed to use large quantities of carbon fibre
A380 (eta. 2006)
Combines Al & GRP as a multilayer material (GLARE)
25% weight saving & less susceptible to fatigue than Al
40% CFRP for wingbox = 1.5t weight saving
16% by weight total composites
787 Dreamliner (eta. 2007)

50% structural weight composites = 25t of CFRP per aircraft
Key driving factors are reductions in the cost to manufacture quality parts
17% fuel reduction over current generation
Demand outstripping supply
24
A38
0
25
Commercial aerospace use
26
Military aerospace use
Development of composite military aerospace applications

27
Where do we find
composites now?
Glass Fibre
28
Where do we find
composites now?
Carbon Fibre
29
Where do we find
composites now?
MMCs & CMCs
30
Composites driving forces

Criteria on which composites are selected depend on the
industry in which they will be used
Aerospace: mainly weight reduction with increased stiffness/strength
High scrap levels are (were?) tolerated
There is a preference for high performance materials in order to reach the weight savings
Performance
Fibres need to be continuous and volume fractions need to be high
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Aerospace:
Strength, stiffness,
weight, quality control
Mechanical Industry:
Design, strength, quality
1/Cost
Automotive:
Transportation: Emphasis is on
decreasing cost
Return on investment, complex
shapes, recycling, etc.
Need to reduce weight as increased
safety requirements = heavier
vehicles = worse fuel economy
Manufacturing routes need to be
low-cost and high speed: fibre
volume fractions not so much of an
issue
Automated fabrication
31
Why composites?
Monolithic materials contain numerous flaws and cracks
This causes them to fail below their theoretical breaking point as the propagation of the flaw causes
failure of the material
Fibre form still contains the same number of random flaws

However they are restricted to a small number of fibres with the remainder exhibiting the
materials theoretical strength
If a flaw causes failure within a fibre, it will not propagate to fail the entire assemblage of fibres
The fibres therefore more accurately reflect the optimum performance of the material
32
Why composites?
Fibres alone can only exhibit tensile properties along the fibres length
similar to fibres in a rope
Need resin to bind them together
Composites can be engineered for
high strengths and stiffnesses

ease of moulding complex shapes
high environmental resistance
low densities, etc.
The resultant material is superior to metals for many applications!
33
The benefits of composite materials are traditionally based on

the following:
Corrosion resistance
Lightweight
High strength
High stiffness
34
Multifunctional materials: Structure of wood

Wood is a natural composite
Requirements:
It has to be tall and straight
It must be strong and light and resist
bending forces
Controlled heat dissipation
Controlled moisture retention ... Etc.
It is composed of multiple fibre bundles
(lamellae) each of which contains multiple
layers of cellulose fibres in a lignin matrix
Lamellae are aligned on the long axis of
the wood
Superior bending and longitudinal stiffness
Alignment of cellulose fibres within

lamellae indicates stiffness & strength of
the wood
MSc Composites Science & Engineering
35
Anisotropy of wood
Effects of Anisotropy:
Material has high stiffness and strength along fibres, but cracks can also
easily propagate along it
Cracks very difficult to propagate across the fibres
36
Wood composites
Bamboo:
Layered natural wood
composite
Plywood:
Thin sheets of veneer that are crosslaminated and glued together with a hotpress
Grain of each layer is positioned in a
perpendicular direction to the adjacent layer
Odd number of layers so that the panel is
balanced around its central axis
37
Structure of bone
Bone:
Compact/cortical bone is the
structural part of bones
Consists of multiple osteons
within a matrix of old osteons
Osteons are aligned in the
direction of applied load
Structurally, each osteon is
composed of multiple lamellae
in a plywood type arrangement
(compact bone is known as
lamellar bone in adults)
Within each osteons are
hydroxyapatite whiskers in a
collagen matrix
Outer lamellae
Osteons
Inner lamellae
38
Engineered materials
Fibres provide strength and
stiffness
Resin acts as a
binder and spreads the load

applied to the composite between
each of the individual fibres and
protects the fibres from damage
controls the transverse properties
Tensile Stress
Fibre
Composite
Resin
Tensile Strain
The combination of resin and reinforcing fibres produces a composite whose

properties are a combination of the properties of each of the constituents
Overall, the properties of the composite are determined by the:
Properties of the fibre (provide stiffness & strength)
Properties of the resin
Ratio of fibre to resin (Fibre Volume Fraction)
The geometry and orientation of the fibres
39
Reinforcements
Glass fibres
Carbon fibres
Original structural reinforcement

& most common
Competitively priced & widely
available
Ease of processing & good
handleability.
Best known & most widely used

high performance fibre
Wide range of mechanical
properties
Linear stress-strain behaviour
E-glass: Most common glass fibre

Useful balance of mechanical,
chemical & electrical properties
Strength
Stiffness
Density
Diameter
Cost
3.45 GPa
75.8 GPa
2.56 g/cm3
8-15 m
~70-150 /kg
Typical properties of carbon fibres

Strength
Stiffness
Density
Diameter
Cost
3.5-6.4 GPa
240-310 GPa
~1.85 g/cm3
5-10 m
~1000-3000 /kg
40
Reinforcements
Aramid fibres
Organic fibre
High tensile stiffness & strength
Low stiffness = ballistic grade
High stiffness = reinforcement
grade
Very poor compressive properties

(similar to that of glass fibres)
Most commonly known as
Kevlar
Kevlar-49: Most common aramid

reinforcement fibre
Strength
Stiffness
Density
Diameter
Cost
3.45 GPa
180 GPa
~1.4 g/cm3
~12 m
~1000-2000 /kg
SiC & Alumina

Used in MMCs and CMCs
Good thermal stability
Boron fibres
Monofilament wires
Excellent strength and stiffness
More expensive than carbon fibres
Used in PMCs and MMCs
High performance
thermoplastics
Highly drawn UHMWPE
Natural fibres
Derived from plants, i.e. ecofriendly
41
Comparison of (UD) composite properties
Unidirectional (UD) Carbon properties are the highest of all common composites
Aramid fibres have excellent tensile properties but weak compressive properties
S-Glass (high strength glass fibres) approach the tensile stiffness of aramids,
strengths of HS Carbon in addition to very high failure strains
E-Glass is a general all-rounder that possesses high failure strains
42
Comparative fibre costs
Woven fabric - yarn
UD fabric - roving
43
Matrices thermosetting resins

Polyester resins
Most commonly used resins &
wide range of formulations,
curing agents, etc.
Acceptable mechanical properties
& acceptable environmental
durability
Very good adhesion to glass fibre
High styrene emissions & high
shrinkage on cure
Typical properties of unsaturated polyesters
Strength
Stiffness
Strain to failure
Density
Cost
55-90 MPa
3.4-4.4 GPa
1.6-4.5 %
1.1-1.5 g/cm3
~70-150 /kg
Vinyl ester resins

Similar processing to polyesters
Very high chemical and
environmental resistance
Better overall properties to
polyesters
Higher cost
Typical properties of vinyl esters
Strength
Stiffness
Strain to failure
Density
Cost
60-93 MPa
2.9-3.9 GPa
3.0-16 %
1.0-1.3 g/cm3
~150-300 /kg
44
Matrices thermosetting resins
Epoxy resins
Most used resin for advanced
composites
Very good mechanical and
thermal properties
Good water resistance
Low shrinkage on cure
Needs proper mixing formulation
Expensive
High fire resistance & excellent

thermal properties
Cure by condensation reaction
resulting in voidy laminate
Bismalemides (BMI)
Superior to epoxies for hot/wet use &
suitable for high operational temps.
>3500 /kg
Typical properties of epoxies

55-130 MPa
2.5-6.0 GPa
3.1-15 %
1.1-1.4 g/cm3
~200-1000 /kg
Cyanate esters
Superb electrical properties & low
moisture absorbance
Used in radomes, antennas, etc
Very expensive (~3000 /kg)
Strength
Stiffness
Strain to failure
Density
Cost
Phenolics
Polyimides
Higher operational temps. than BMI
Cures similar to phenolics
Extremely expensive (>5500 /kg)
45
Matrices thermoplastic resins

Thermoplastic resins
Offer
Increased toughness
Higher strain to failure than
thermosets
Improved impact resistance
Improved hot/wet resistance:

They do not absorb any
significant amount of water but
are subject to chemical attack
Indefinite shelf life
Engineering thermoplastics
PA (Polyamide)
Can be molten and moulded as

needed
Problem
Operational temperature must be
below the Tg
Subject to creep at high
temperatures
Self-lubricating & exhibit good

abrasion resistance
Good chemical resistance but
high water absorption
PP (Polypropylene)
Low density & low cost
High impact properties
PET (Polyester terephtalate)
Comparable processing to PP
Higher service temperature &
Stiffer than PP
PEEK (Polyether ether ketone)
Highest performing engineering
thermoplastic
High cost & cost of processing
46
Matrices other
Metal matrices
Aluminium
Most common reinforced metal
Typically used as a pre-mixed
casting alloy but wrought alloy
can be used for infiltration
casting
Ceramic matrices
Use of ceramic matrix is to
improve poor toughness
characteristics of these matrices
Very few applications exist, most
common being Carbon/Carbon
brakes.
Titanium
Typically used with continuous
reinforcement due to difficulty
with processing titanium
Others
Other metals, e.g. Cu, Be, Ag,
used to retain their excellent
thermal and electrical properties
and improve their thermal
expansion/ wear resistance
47
Specific property = property / density
Consider the properties of

the individual constituents:
The mechanical properties of the
fibres are superior to monolithic
materials especially as they are
light weight.
resins are worse than most
engineering materials
composite depends on the
placement of the reinforcement
Composites possess superior specific stiffness and strength than steel.

However this mostly occurs when properties are measured in the direction of the
fibres.
48
Composite material:
Often formed at the same time as the
end-product is being fabricated ;
This means that the person who makes
the end-product creates the properties
of the material in use
Composite
Metals &
Alloys
Stress
Metals:
Properties are largely determined by
material supplier;
End-processors can do little to change
those 'in-built' properties
Composite
Strain
Because of the large variation in material parameters including fibre strength,

stiffness, volume fraction, length and orientation it is possible to engineer or
design the required properties and the direction in which they are required.
49
Controlling Anisotropy
Effects of anisotropy
Aligning fibres in direction of load
(i.e. producing unidirectional
composite) produces the highest
properties
Perpendicular load carrying capacity
becomes rather poor
Can be relieved by placing fibres in
transverse direction, but lowers
effective properties
There are three levels of orientation

Random (quasi-isotropic properties)
Cross-ply (transversely isotropic)
Unidirectional (orthotropic)
50
Benefits from anisotropy
Orienting the reinforcements in the direction of the applied loads has a

significant effect on the properties of the final composite
Properties are roughly equal to the stiffness volume fraction of the
fibres
In unidirectional orientation, there are more fibres in the loading direction
than in the random orientation
51
Effect of aligning fibres
For random orientations,

improvement of properties
over metallic materials is
not that significant.
Need to use CFRP which
equates to higher costs
52
Strengths
Weight reduction
High specific stiffness & strength
Low maintenance cost

Corrosion resistance
Design flexibility & integrated parts

Large, complex structures can be created in one piece
Pigmentation and textures can be incorporated directly into the
composite at the manufacturing stage
Environmentally friendly
Low energy consumption in manufacture.
Safety
Crush structures
Durability
Carbon fibre reinforced plastics possess excellent fatigue properties
Glass fibre reinforced plastics are excellent electrical insulators
53
Comparison with other materials:

Stiffness & Strength
Stiffness
traditional
materials
composite
materials
Strength
Properties will vary with fibre
contents and orientations.
Lowest property for short &
random fibre composites, and
highest for UD fibre prepregs.
54

Density
Density: Composite materials

have a very low density
compared to metals and are
therefore of interest for lightweight design
55

Specific Properties
Specific stiffness
Specific strength
56
Why composites?
Integrated parts
57
Safety
Composites absorb more energy
per kilo than metals in a crash
Crushing pattern is stable unlike
that of metals that fail by buckling
Composites exploited in Formula 1
(since 1982) and trains
Initial Peak Load
Average Crush Load
Load (kN)
Load Fluctuation
Amplitude
Region of
sustained crush
Displacement (mm)
58
59
Composite weaknesses
Costs of processing still high
Most processing methods require a huge investment in manual labour and/or machinery
Absence of mass production technology for high-performance composites

Typical routes are pre-preg which is performed either by manual layup or by tape layup
Recycling of thermosets impractical

Only real route apart from regrinding as filler is pyrolysis
Recycling of thermoplastics with glass fibres difficult

Option is to regrind long-fibre composites as lower grades for injection moulding
Lack of knowledge in designing with anisotropic materials
60
Composite weaknesses (cont)

Uncertainty regarding long-term properties
Factors such as moisture degradation, damage tolerance after impact requires large safety margins
in design
Uncertainties in predicting failure modes

Crack propagation mechanisms, damage tolerance after impact delamination etc
Aircraft industry works on a zero crack tolerance approach (structures are therefore over
designed)
Inadequate industrial capacity (world annual production of carbon only about 30,000
tonnes/annum)
The use of just 20% structural weight of carbon in the Airbus A380 is consuming all excess
production
61
Performance versus Production

Ideal situation for composite takeup
would be to have high modulus
parts capable of being produced at
over 1000 parts per day
62
Factors favourable for metal substitution

Composites are seldom used for just one benefit
It is usual that a combination of properties is required before they are
used to substitute for alternative materials.
Most successful composite designs are NOT direct shape

replacements for an existing metal component.
Design should incorporate aspects of the composite
Features such as anisotropy and mouldability should be used to achieve
a cost effective product.
The gain achieved in using composites to

achieve these objectives is greater than the
costs associated with using composites
63
Inefficient manufacturing processes
Prepreg (autoclave) prepregs were expensive

Capital equipment (Autoclaves, tape layers) are expensive, material
deposition rates and processing are slow
More than 70% of part cost from fabrication!
64
Costs
$ saved (Fuel) / kg weight reduction per lifetime
Car <1
Subway 15
Aircraft 200
Satellite 5,000
65
Future opportunities
Off-shore applications
Alternative energy
Infrastructure repair
Sustainable development
Passenger cars
66
Threats to composite industry

Recycling legislation
Composite recycling is relatively difficult compared to metals and techniques for recycling are
still in their infancy
Rise in cost of oil

This has significantly impacted the cost of the resins over the past year
Drop in cost of oil/fuel

Less drive for weight saving in aircraft structures
Public misconceptions/ high profile failures

Failures such as that of Team Phillips (high-speed catamaran) due to delamination between the
carbon skins and the core
Metals fight back!

Aluminium industry keeps evolving: new alloys improve strength etc.
67
Eco-composites
Natural fibre composites
Can be considered as a carbon sink
Properties of natural fibre composites
can be almost as good as glass fibre
All-PP composites
100% recyclable (no
need to separate fibres
from resin)
68
Barriers for progress

Materials
Poor understanding of structure-property relationships
Selection driven or limited by raw material costs, recycling and manufacturing technology
Design
Lack of knowledge of designing with anisotropic materials
Lack of knowledge of designing for durability
Design limited by manufacturing technology
Manufacturing
Absence of mass production technology (Cycle time < 1 min)
Requirement for same or lower costs than metals!
69
Systems approach to designing with

composites
Materials
Design
Manufacturing
70
Department of
Mechanical
Engineering
Mohammad Ali Jinnah

University
Islamabad Campus
Thank you!
71

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Mohammad Ali Jinnah

Dr Rizwan Saeed Choudhry

BE (NUST, Pakistan - 2002)

Mohammad Ali Jinnah

About the Course

Mohammad Ali Jinnah

Books and References

Mohammad Ali Jinnah

Mohammad Ali Jinnah

Mohammad Ali Jinnah

Mohammad Ali Jinnah

Composite Materials - Basics

usually having distinct properties which remain distinct even after

Introduction What are composites?

The different constituents must have

In almost all cases, there is a

Structural composites typically refer

Mohammad Ali Jinnah

Mohammad Ali Jinnah

PMCs are used in the greatest diversity of composite applications, as well as in

They can also be categorised into short-fibre reinforced composites, or

Mohammad Ali Jinnah

Metal Matrix Composites (MMCs)

Ceramic Matrix Composites (CMCs)

Mohammad Ali Jinnah

Continuous fibre strands or roving

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The second level of classification is by reinforcement form

To provide a useful increase in properties, the reinforcement has to be

Structural alloys susceptible to corrosion

Gordon Aerolite Spitfire

Mohammad Ali Jinnah

Mohammad Ali Jinnah

Energy crisis provided incentive for introduction of

Mohammad Ali Jinnah

Increased use of composites in military and commercial

Development of fibreglass structures for boats and marine

Major applications of PMCs in the 80s

New tough composites used for bigger composite wings on F-18E/F

Mohammad Ali Jinnah

World market in 1999 was 2500tons

Mohammad Ali Jinnah

787 Dreamliner (eta. 2007)

Demand outstripping supply

Commercial aerospace use

Military aerospace use

Development of composite military aerospace applications

Composites driving forces

Fibres need to be continuous and volume fractions need to be high

Fibre form still contains the same number of random flaws

Composites can be engineered for

high strengths and stiffnesses

The resultant material is superior to metals for many applications!

The benefits of composite materials are traditionally based on

Multifunctional materials: Structure of wood

Alignment of cellulose fibres within

MSc Composites Science & Engineering

binder and spreads the load

The combination of resin and reinforcing fibres produces a composite whose

Original structural reinforcement

Best known & most widely used

E-glass: Most common glass fibre

MSc Composites Science & Engineering