Chapter 16: Composite Materials

Chapter 16 - 1

Composites
Combination of materials with the objective of getting a more desirable properties Ex: get flexibility & weight of a polymer plus the strength of a ceramic Principle of combined action Mixture gives averaged properties

Chapter 16 - 2

Terminology/Classification
Composites: Matrix:
-- Multiphase material w/significant proportions of each phase. -- The continuous phase -- Purpose is to:
- transfer stress to other phases - protect phases from environment

woven fibers

0.5 mm
cross section view

-- Classification:
metal

MMC, CMC, PMC

polymer

ceramic

Dispersed phase:
-- Purpose: enhance matrix properties.
MMC: increase sy, TS, creep resist. CMC: increase Kc PMC: increase E, sy, TS, creep resist.

0.5 mm
Reprinted with permission from D. Hull and T.W. Clyne, An Introduction to Composite Materials, 2nd ed., Cambridge University Press, New York, 1996, Fig. 3.6, p. 47.

-- Classification: Particle, fiber, structural

Chapter 16 - 3

Chapter 16 - 4

Composite Survey
Composites

Particle-reinforced

Fiber-reinforced

Structural

Largeparticle

Dispersionstrengthened

Continuous (aligned)

Discontinuous (short)

Laminates

Sandwich panels

Aligned

Randomly oriented

Adapted from Fig. 16.2, Callister 7e.

Chapter 16 - 5

Composite Survey: Particle-I

Particle-reinforced Examples: - Spheroidite matrix: ferrite (a) steel
(ductile)

Fiber-reinforced

Structural
particles: cementite (Fe3 C) (brittle)
Adapted from Fig. 10.19, Callister 7e. (Fig. 10.19 is copyright United States Steel Corporation, 1971.)

60 mm

- WC/Co cemented carbide

matrix: cobalt (ductile) Vm : 10-15 vol%!

particles: WC (brittle, hard)

600 mm

Adapted from Fig. 16.4, Callister 7e. (Fig. 16.4 is courtesy Carboloy Systems, Department, General Electric Company.)

- Automobile matrix: rubber tires

(compliant)

particles: C (stiffer) 0.75 mm

Adapted from Fig. 16.5, Callister 7e. (Fig. 16.5 is courtesy Goodyear Tire and Rubber Company.)

Chapter 16 - 6

Composite Survey: Particle-II

Particle-reinforced Fiber-reinforced Structural

Concrete gravel + sand + cement

- Why sand and gravel? Sand packs into gravel voids

Reinforced concrete - Reinforce with steel rerod or remesh

- increases strength - even if cement matrix is cracked

Prestressed concrete - remesh under tension during setting of

concrete. Tension release puts concrete under compressive force - Concrete much stronger under compression. - Applied tension must exceed compressive force

Post tensioning tighten nuts to put under tension

threaded rod
Chapter 16 - 7

nut

Composite Survey: Particle-III

Particle-reinforced Fiber-reinforced Structural

Elastic modulus, Ec, of composites:

-- two approaches.
E(GPa) 350 Data: Cu matrix 30 0 w/tungsten 250 particles 20 0 150

upper limit: rule of mixtures Ec = VmEm + VpEp lower limit: 1 Vm Vp = + Ec Em Ep

20 4 0 6 0 8 0 10 0 vol% tungsten
Adapted from Fig. 16.3, Callister 7e. (Fig. 16.3 is from R.H. Krock, ASTM Proc, Vol. 63, 1963.)

(Cu)

(W)

Application to other properties:

-- Electrical conductivity, se: Replace E in equations with se. -- Thermal conductivity, k: Replace E in equations with k.
Chapter 16 - 8

Composite Survey: Fiber-I

Particle-reinforced Fiber-reinforced Structural

Fibers very strong Provide significant strength improvement to material Ex: fiber-glass
Continuous glass filaments in a polymer matrix Strength due to fibers Polymer simply holds them in place

Chapter 16 - 9

Composite Survey: Fiber-II

Particle-reinforced Fiber-reinforced Structural

Fiber Materials
Whiskers - Thin single crystals - large length to diameter ratio graphite, SiN, SiC high crystal perfection extremely strong, strongest known very expensive Fibers polycrystalline or amorphous generally polymers or ceramics Ex: Al2O3 , Aramid, E-glass, Boron, UHMWPE Wires Metal steel, Mo, W

Chapter 16 - 10

Fiber Alignment
Adapted from Fig. 16.8, Callister 7e.

aligned continuous

aligned random discontinuous

Chapter 16 - 11

Composite Survey: Fiber-III

Particle-reinforced Fiber-reinforced Aligned Continuous fibers Examples:
-- Metal: g'(Ni3Al)-a(Mo)

Structural

-- Ceramic: Glass w/SiC fibers

formed by glass slurry Eglass = 76 GPa; ESiC = 400 GPa.

matrix: a (Mo) (ductile)

by eutectic solidification.

(a)

fracture surface
From F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig. 4.22, p. 145 (photo by J. Davies); (b) Fig. 11.20, p. 349 (micrograph by H.S. Kim, P.S. Rodgers, and R.D. Rawlings). Used with permission of CRC Press, Boca Raton, FL. Chapter 16 - 12

2 mm

fibers: g (Ni3Al) (brittle)

From W. Funk and E. Blank, Creep deformation of Ni3Al-Mo in-situ composites", Metall. Trans. A Vol. 19(4), pp. 987-998, 1988. Used with permission.

(b)

Composite Survey: Fiber-IV

Particle-reinforced Fiber-reinforced Discontinuous, random 2D fibers Example: Carbon-Carbon
-- process: fiber/pitch, then burn out at up to 2500C. -- uses: disk brakes, gas turbine exhaust flaps, nose cones.
(b)

Structural
C fibers: very stiff very strong

C matrix: less stiff view onto plane less strong fibers lie in plane

(a)

Other variations:
-- Discontinuous, random 3D -- Discontinuous, 1D
Adapted from F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig. 4.24(a), p. 151; (b) Fig. 4.24(b) p. 151. (Courtesy I.J. Davies) Reproduced with permission of CRC Press, Boca Raton, FL. Chapter 16 - 13

Composite Survey: Fiber-V

Particle-reinforced Fiber-reinforced Structural Critical fiber length for effective stiffening & strengthening:
fiber strength in tension

sf d fiber length 15 tc

fiber diameter
shear strength of fiber-matrix interface

Ex: For fiberglass, fiber length > 15 mm needed Why? Longer fibers carry stress more efficiently!
Shorter, thicker fiber:
s(x)

sf d fiber length 15 tc
Adapted from Fig. 16.7, Callister 7e.

Longer, thinner fiber:

fiber length 15
s(x)

sf d tc

Poorer fiber efficiency

Better fiber efficiency

Chapter 16 - 14

Composite Strength: Longitudinal Loading

Continuous fibers - Estimate fiber-reinforced composite
strength for long continuous fibers in a matrix Longitudinal deformation

sc = smVm + sfVf
volume fraction

but

c = m = f
isostrain

Ece = Em Vm + EfVf

longitudinal (extensional) modulus f = fiber m = matrix

Ff EfVf Fm EmVm

Chapter 16 - 15

Composite Strength: Transverse Loading

In transverse loading the fibers carry less of the load - isostress sc = sm = sf = s c= mVm + fVf
1 Vm Vf Ect Em Ef

transverse modulus

Chapter 16 - 16

Composite Strength
Particle-reinforced Fiber-reinforced Structural

Estimate of Ec and TS for discontinuous fibers:

sf d -- valid when fiber length 15 tc

-- Elastic modulus in fiber direction:

Ec = EmVm + KEfVf
efficiency factor:
-- aligned 1D: K = 1 (aligned ) -- aligned 1D: K = 0 (aligned ) -- random 2D: K = 3/8 (2D isotropy) -- random 3D: K = 1/5 (3D isotropy)
Values from Table 16.3, Callister 7e. (Source for Table 16.3 is H. Krenchel, Fibre Reinforcement, Copenhagen: Akademisk Forlag, 1964.)

-- TS in fiber direction:

(TS)c = (TS)mVm + (TS)fVf

(aligned 1D)
Chapter 16 - 17

Composite Production Methods-I

Pultrusion
Continuous fibers pulled through resin tank, then preforming die & oven to cure

Adapted from Fig. 16.13, Callister 7e. Chapter 16 - 18

Composite Production Methods-II

Filament Winding
Ex: pressure tanks Continuous filaments wound onto mandrel
Adapted from Fig. 16.15, Callister 7e. [Fig. 16.15 is from N. L. Hancox, (Editor), Fibre Composite Hybrid Materials, The Macmillan Company, New York, 1981.]

Chapter 16 - 19

Composite Survey: Structural

Particle-reinforced Fiber-reinforced Structural

Stacked and bonded fiber-reinforced sheets -- stacking sequence: e.g., 0/90

-- benefit: balanced, in-plane stiffness
Adapted from Fig. 16.16, Callister 7e.

Sandwich panels
-- low density, honeycomb core -- benefit: small weight, large bending stiffness
face sheet adhesive layer honeycomb
Adapted from Fig. 16.18, Callister 7e. (Fig. 16.18 is from Engineered Materials Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)

Chapter 16 - 20

Composite Benefits
CMCs: Increased toughness
Force
particle-reinf

PMCs: Increased E/r

103
ceramics

E(GPa) PMCs 2 10 10

fiber-reinf un-reinf

metal/ metal alloys

Bend displacement
10 -4
6061 Al ss (s-1) 10 -6

.1 G=3E/8 polymers .01 K=E .1 .3 1 3 10 30 Density, r [mg/m3]

MMCs:

Increased creep resistance

10 -8

10 -10

6061 Al w/SiC whiskers

Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp. 139-146, 1984. Used with permission.

20 30 50

s(MPa) 100 200

Chapter 16 - 21

Summary
Composites are classified according to:
-- the matrix material (CMC, MMC, PMC) -- the reinforcement geometry (particles, fibers, layers).

Composites enhance matrix properties:

-- MMC: enhance sy, TS, creep performance -- CMC: enhance Kc -- PMC: enhance E, sy, TS, creep performance Particulate-reinforced: -- Elastic modulus can be estimated. -- Properties are isotropic. Fiber-reinforced: -- Elastic modulus and TS can be estimated along fiber dir. -- Properties can be isotropic or anisotropic. Structural: -- Based on build-up of sandwiches in layered form.
Chapter 16 - 22

Chapter 16 - 23