Elective Course (2) - Composite Materials MET 443
Uploaded by
يوسف عادل حسانينElective Course (2) - Composite Materials MET 443
Uploaded by
يوسف عادل حسانينCairo University
Faculty of Engineering
Mining, Petroleum and Metallurgy Department
4th Year Metallurgy
Elective Course (2) -
Composite Materials
MET 443
LECTURE 1
By Dr. Ahmed Hatem Al-Khoribi
• Course Contents
• Definitions.
• Classifications.
• Applications.
• Fibers.
• Matrices.
• Additives.
• Manufacturing.
• Mechanics.
• Grades:
• Class work grades = 30.
• Final exam grades = 70.
• Definition
• The three traditional primary classifications of
materials are: metals, ceramics, and polymers.
• When combining materials from these different
categories, or even different materials within
each category, in such a way as to achieve
properties and performance that are unique.
Such materials are called composites.
• Composite material is a material brought about
by combining materials differing in composition
or form on a macro-scale for the purpose of
obtaining specific characteristics and
properties.
• Composite Constituents
• Usually, composites consists of two
constituents.
• The body constituent gives the composite its
bulk form, and it is called the matrix. The other
component is a structural constituent, also
called the reinforcement, which determines
the internal structure of the composite.
• The region between the body and structural
constituents is called the interphase. This
interphase has its own properties.
• Interphase properties play a very important role in determining
the ultimate properties of the bulk composite. For instance, the
interphase is where mechanical stresses are transferred
between the matrix and the reinforcement. The interphase is
also critical to the long-term stability of a composite. It will be
assumed that there is always an interphase present in a
composite, even though it may have a thickness of only an
atomic dimension.
Figure shows composite constituents.
• Composite Classification
• Composite materials can be classified into two
main categories:
1. Fiber-reinforced Composites.
2. Particle-reinforced Composites (Particulate
Composites).
1. Fiber-reinforced Composites
• A fiber is a material made into a long filament. A
single fiber is called a filament. The filament is
very thin and has very small diameter (diameter
ranges from 5 to 15 m).
• The bonding between fibers and matrices is
created during the manufacturing phase of the
composite material. This has fundamental
influence on the mechanical properties of the
composite material.
• Fiber-reinforced composites can be classified into
two categories:
1. Continuous-fiber-reinforced composites.
2. Discontinuous-fiber-reinforced composites.
• The figure below shows continuous and
discontinuous fibers.
1. Continuous-fiber-reinforced Composites
• These are the composites that consist of long
continuous fibers that are aligned together in
definite directions. They are used in the form
of continuous bundles or woven into sheets
(like cloth fabrics) known as preform.
2. Discontinuous-fiber-reinforced Composites
• These are the composites that consist of short
discontinuous fibers that can either be aligned
together in definite directions OR randomly
oriented. They are used in the form of
discontinuous bundles or woven into mats
(fabrics of discontinuous random fibers).
• Short fibers are with lengths of the order of a
fraction of a millimeter to a few centimeters.
2. Particle-reinforced Composites (Particulate
Composites)
• Particulate composites include a wide range
of materials, from cement reinforced with
rock aggregates (concrete) to mixtures of
ceramic particles in metals, called cermets.
• In all cases, however, the particulate
composite consists of a reinforcement that
has similar dimensions in all directions
(roughly spherical), and all phases in the
composite bear a proportion of an applied
load.
• The percentage of particulates in this class of
composites range from a few percent to 70%.
• Particle-reinforced composites can be
classified into two categories:
1. Metal matrix composites.
2. Polymer matrix composites.
• Note: This classification is based on matrix
nature/type.
1. Metal Matrix Composites
• They include structural parts, electrical contact
materials, metal-cutting tools, and magnet
materials and are formed by incorporating
metallic or ceramic particulates metal matrices
through traditional powder metallurgical or
casting techniques.
• Metallic particulates include tungsten (W),
molybdenum (Mo) and other refractory
materials.
• Ceramic particulates include oxides (alumina,
magnesia, silica, …) and carbides (tungsten
carbide, chromium carbide, titanium carbide, …).
Cermets are formed by traditional powder-
metallurgical techniques.
2. Polymer Matrix Composites
• They are composed of particulate fillers such
as silica, alumina (and other metal oxides),
silicates, carbonates, wood, clay, or glass
micro-spherical fillers in phenol, epoxy,
polyester, or thermoplastic matrices.
• Note: Any reinforcement can be generally
referred to as “filler.” However, the term filler
is usually used to refer to particulate
reinforcements.
• Applications of Composites:
1. Electricity and Electronics:
a. Insulation for electrical construction.
b. Supports for circuit breakers.
c. Supports for printed circuits.
d. Armors, boxes, covers.
e. Antennas.
f. Tops of television towers.
g. Cable tracks.
h. Wind turbines.
2. Buildings and Public Works:
a. Houses.
b. Chimneys.
c. Concrete molds.
d. Various covers (domes, windows, etc.).
e. Swimming pools.
f. Facade panels.
g. Profiles.
h. Partitions, doors, furniture, bathrooms.
3. Road Transport:
a. Body components.
b. Complete body.
c. Wheels, shields.
d. Transmission shafts.
e. Suspension springs.
f. Suspension arms.
g. Casings.
h. Cabins, seats.
i. Highway tankers, isothermal trucks.
j. Trailers.
4. Air Transport:
a. All-composite gliders.
b. All-composite light aircraft and drones.
c. Many aircraft components: vertical and
horizontal tail plane, wing boxes, leading
edges, winglets, doors, aircraft brake disks.
d. Many helicopter components: blades, main
rotors, tail rotors, transmission shafts, cabins,
tails.
e. Aircraft engines: propellers, blades.
5. Space Transport:
a. Bodies.
b. Tanks.
c. Nozzles.
d. Heat shields for atmospheric reentry.
6. Rail Transport:
a. Fronts of locomotives.
b. Wagons.
c. Doors, seats, interior panels.
d. Ventilation housings.
e. Structural parts.
7. Sports and Leisure:
a. Tennis and squash rackets.
b. Fishing poles.
c. Skis, snowboards.
d. Windsurfing boards, sailboards,
skateboards.
e. Bows and arrows.
f. Javelins (spears).
g. Protection helmets.
h. Bicycles.
i. Golf clubs.
j. Oars (for rowing boats), vessels for racing.