ECE 2201- GROUP 3

GROUP 3- COMPOSITES

MAGNAYE, CRIS PAUL

REPORTER LAGUARDIA, ALLYSA

VILLAREAL, ISAAC MIGUEL DIAZ, JOHN ALFRED

MENDOZA, CARLIN JOSH GASANGUE, DIANA MARIE

Composite materials are materials Composite materials can be made
made from two or more different types from a wide range of materials,
of materials that, when combined, including plastics, metals,
have different and often superior ceramics, and natural fibers.
properties compared to the individual
These materials are combined
components. The two or more
materials are typically distinct and are using a variety of techniques,
physically and chemically combined in such as layering, bonding, or
a way that enhances their performance embedding, to create a material
characteristics. with unique properties.
Composites, also known as Fiber- In many of our industry’s products, polyester
Reinforced Polymer (FRP) composites, are resin is the matrix and glass fiber is the
reinforcement. But many combinations of
made from a polymer matrix that is
resins and reinforcements are used in
reinforced with an engineered, man-made composites—and each material contributes
or natural fiber (like glass, carbon or to the unique properties of the finished
aramid) or other reinforcing material. The product: Fiber, powerful but brittle, provides
matrix protects the fibers from strength and stiffness, while more flexible
environmental and external damage and resin provides shape and protects the fiber.
transfers the load between the fibers. The FRP composites may also contain fillers,
additives, core materials or surface finishes
fibers, in turn, provide strength and
designed to improve the manufacturing
stiffness to reinforce the matrix—and help process, appearance and performance of the
it resist cracks and fractures. final product.
 Example:
Composites can be natural or Plywood is a man-made
synthetic. Wood, a natural composite, composite that combines natural
is a combination of cellulose or wood and synthetic materials. Thin
fibers and a substance called lignin.
layers of wood veneer are bonded
The fibers give wood its strength; lignin
is the matrix or natural glue that binds together with adhesive to form
and stabilizes them. Other composites flat sheets of laminated wood
are synthetic (man-made). that are stronger than natural
wood.
Not all plastics are composites. In fact,
Polymer resins (such as polyester,
most plastics—the ones used in toys,
water bottles and other familiar items vinyl ester, epoxy or phenolic) are
—are not composites. They’re pure sometimes referred to as plastic.
plastics. But many types of plastic can
be reinforced to make them stronger.
This combination of plastic and
reinforcement can produce some of
the strongest, most versatile materials
(for their weight) ever developed by
technology.
One of the earliest uses of composite In the 12th century A.D., Mongol warriors used
material was by the ancient Mesopotamians composite materials (bamboo, silk, cattle tendons
and horns, and pine resin) to craft archery bows
around 3400 B.C., when they glued wood
that were swifter and more powerful than those
strips at different angles to create plywood. of their rivals: They put the tendons on the
The concept of “composite” building tension (outer) side and sheets of horn on the
construction has existed since ancient compression (inner) side of the bow over a core of
times. Civilizations throughout the world bamboo. They tightly wrapped the structure with
have used basic elements of their silk and sealed it with pine resin. A museum
tested some of the surviving bows, now more
surrounding environment in the fabrication than 900 years old, and found that the old bows
of dwellings including mud/straw and were nearly as strong as modern ones—and could
wood/clay. “Bricks” were and still are made hit targets as far away as 490 yards (the length of
from mud and straw. nearly five football fields).
STRUCTURE OF COMPOSITE
MATERIALS
The structure of a composite is commonly such that one
of the components is the matrix while the other
components are fillers bound by the matrix, which is
often called the binder.
Composites, the
wondermaterials are
becoming an essential
part of today's materials
due to the
advantagessuch as low
weight, corrosion
resistance, high fatigue
strength, and faster
assembly.
Composites in structural applications have the
following characteristics:

1. They generally consist of two or more

physically distinct and mechanically
separable materials.
2. They are made by mixing the separate
materials in such a way as to achieve controlled
and uniform dispersion of the constituents.
3. They have superior mechanical properties
and in some cases uniquely different from the
properties of their constituent
Advanced composites have
high-performance fiber
reinforcements in a polymer
matrix material such as epoxy.
Examples are graphite/epoxy,
Kevlar/epoxy,and boron/epoxy
composites. Advanced
composites are traditionally
used in theaerospace
industries, but these materials
have now found applications in
commercialindustries as well.
The fabrication and shaping of
composites into finished
products often combines the
formation of the material itself
during the fabrication process.
The important processing
methods are hand lay-up, bag
molding process, filament
winding, pultrusion, bulk
molding, sheet molding, resin
transfer molding, injection
molding,and so on
COMPOSITE MATERIALS HAVE THE
FOLLOWING ADVANTAGES ON ITS STRUCTURE
THAN OTHER MATERIALS

a) High specific strength

b) High specific stiffness
c) High fracture resistance
d) Good abrasion resistance
e) Good impact resistance
f) Good corrosion resistance
g) Good fatigue resistance
h) Low cost/Affordable
 PR OP ER TIES OF
OS IT ES M AT ERIALS
COMP
​Composites are extremely versatile
products.
 HI GH S TRE N GT H
TO W EIG H T RA TIO

Fibre composites are extremely

strong for their weight. By refining
the laminate many characteristics
can be enhanced. A common
la m in at e of 3m m C ho pp ed st ra nd
mat, is quite flexible compared to a
3 mm ply. However it will bend a
long way more than the ply before
yielding. Stiffness should not be
confused with Strength.
 HI GH S TRE N GT H
TO W EIG H T RA TIO

A carbon fibre laminate on the

other hand, will have a stiffness of
m an y ti m es th at of m ild st ee l of th e
same thickness, increased ultimate
strength, yet only be less than 1/4
of it's weight.
 LIGHTWEIGHT
A standard Fibreglass laminate has a
specific gravity in the region of 1.5,
co m pa re d to A llo y of 2. 7 or st ee l of
7.8. When you then start looking at
Carbon laminates, strengths can be
many times that of steel, but only a
fraction of the weight.
 LIGHTWEIGHT
One example is a DVD case lid was
produced using carbon fibre to
reduce the case's overall weight so
that it could be carried as cabin
baggage whilst traveling, and for
improved security. It was used by
support crew for the All Blacks
during their 1999 Rugby World Cup
campaign.
 FIRE RESISTANCE
The ability for composites to
withstand fire has been steadily
improving over the years. There are
two types of systems to be
considered:

Fire Retardant - Are self

extinguishing laminates, usually
m ad e w it h ch lo ri na te d re si ns an d
ad di ti ve s su ch as A nt im on y tr io xi de .
These release CO2 when burning so
when the flame source is removed,
the self extinguish.
 FIRE RESISTANCE
Fire Resistant - More difficult and
made with the likes of Phenolic
Resins. These are difficult to use, are
cured with formaldehyde, and
require a high degree of post curing
to achieve true fire resistance.
 FIRE RESISTANCE
Other materials are also becoming
more readily available to be used as
in tumescent layers, which expand
and blanket the surface, preventing
sp re ad of fla m e. Th er e is a pa in t on
coating usually applied to the back
of the product laminate, plus a thin
fibre film to go under the Gelcoat
giving the outer surface a blanketing
coat as well.
ELECTRICAL PROPERTIES

​ ibreglass Developments Ltd

F
produced the Insulator Support
straps for the Tranz Rail main trunk
electrification. The straps, although
only 4mm thick, meet the required
loads of 22kN, as well as easily
m ee ti ng in su la ti on re qu ir em en ts .
 CHEMICAL & W EATHERING
RESISTANCE
​ omposite products have good
C
weathering properties and resist the
attack of a wide range of chemicals.
This depends almost entirely on the
resin used in manufacture, but by
ca re fu l se le ct io n re si st an ce to al l bu t
the most extreme conditions can be
achieved. Because of this,
composites are used in the
manufacture of chemical storage
tanks, pipes, chimneys and ducts,
boat hulls and vehicle bodies.
 COLOUR
​ lmost any shade of any colour can
A
be in co rp or at ed in to th e pr od uc t
during manufacture by pigmenting
the gelcoat used. Costs are therefore
reduced by no further finishing or
painting. Soluble dyes can be used if
a translucent product is desired.
 TRANSLUCENCY

​ olyester resins are widely used to

P
manufacture translucent mouldings
an d sh ee ts . Li gh t tr an sm is si on of up
to 85% can be achieved.
 DESIGN FLEXIBILITY

​ ecause of the versatility of

B
composites, product design is only
limited by your imagination.
 LOW TH ER M AL
CO ND UC TIVIT Y

​F ib re gl as s D ev el op m en ts ha s be en
invo lv ed in th e de ve lo pm en t an d
prod uc ti on of sp ec ia liz ed m ea t
containers which maintain prime cuts
of chilled meat at the correct
temperature for Export markets. They
ar e m an uf ac tu re d us in g th e RT M
proc es s, w it h sp ec ia l re in fo rc in g an d
foam inserts.
 MAN UFACTURING
ECONOMY

Fibreglass Developments produces

several models of fuel pump covers
for Fuel quip. Fibreglass is an ideal
m at er ia l fo r pr od uc in g it em s of th is
type for many reasons, including
being very economical.
PROCESS OF COMPOSITE
MATERIALS
There are three types of composite manufacturing
processes: open molding, closed molding and cast
polymer molding. There are a variety of processing
methods within these molding categories, each with its own
benefits.
TYPES OF COMPOSITE
PROCESSSES
 OPEN
MOLDING
In open molding, raw materials
(resins and fiber reinforcements) are
exposed to air as they cure or harden.
Open molding utilizes different
processes, including hand lay-up,
spray-up, casting, and filament
winding.
 HAND
LAY-UP
Hand lay-up is an open molding method
suitable for making a wide variety of
composites products from very small to
very large. Production volume per mold is
low; however, it is feasible to produce
substantial production quantities using
multiple molds. Hand lay-up is the simplest
composites molding method, offering low
cost tooling, simple processing, and a wide
range of part sizes. Design changes are
readily made. There is a minimum
investment in equipment. With skilled
operators, good production rates and
consistent quality are obtainable.
SPRAY-UP
In the spray-up process, the operator
controls thickness and consistency,
therefore the process is more operator
dependent than hand lay-up. Although
production volume per mold is low, it is
feasible to produce substantial production
quantities using multiple molds. This
process uses simple, low cost tooling and
simple processing. Portable equipment
permits on-site fabrication with virtually
no part size limitations. The process may
be automated.
FILAMENT WINDING
Filament winding results in a high degree of fiber
loading, which provides high tensile strength in
the manufacture of hollow, generally cylindrical
products such as chemical and fuel storage tanks,
pipes, stacks, pressure vessels, and rocket motor
cases. The process makes high strength-to-weight
ratio laminates and provides a high degree of
control over uniformity and fiber orientation. The
filament winding process can be used to make
structures that are highly engineered and meet
strict tolerances. Because filament winding is
computer-controlled and automated, the labor
factor for filament winding is lower than other
open molding processes.
LEARN MORE
 What Do You Know ABout

closed molding?
In closed-molding, raw materials (fibers and resin) cure inside a two-sided mold or within a vacuum bag (shut off
from air). Closed-molding processes are usually automated and require special equipment, so they’re mainly used
in large plants that produce huge volumes of material—up to 500,000 parts a year.

MORE INFORMATION
TYPES OF CLOSED
MOLDING
1 VACUUM BAG MOLDING 5 PULTRUSION

VACUUM INFUSION REINFORCED REACTION

2 6
PROCESSING INJECTION MOLDING

RESIN TRANSFER
3 7 CENTRIFUGAL CASTING
MOLDING

COMPRESSION CONTINUOUS
4 8
MOLDING LAMINATION
VACUUM This manufacturing process is designed to
improve the mechanical properties of
BAGGING laminate (two or more layers of fiber
reinforcement bonded with a resin). A
vacuum is created to force out trapped air
and excess resin, compacting the
laminate. High-fiber concentration
provides better adhesion (between layers
of sandwich construction). In addition,
vacuum bag molding helps eliminate
excess resin that builds up when
structures are made using (open-molding)
hand lay-up techniques.
 VACUUM
INFUSION
PROCESSING

Vacuum infusion processing (VIP) is a technique that uses

vacuum pressure to drive resin into a laminate. Vacuum
infusion is typically used to manufacture very large structures.
Vacuum infusion produces strong, lightweight laminates and
offers substantial emissions reductions (compared to open-
molding processing and wet lay-up vacuum bagging). This
process uses the same low-cost tooling as open molding and
requires minimal equipment.
RESIN TRANSFER
MOLDING
Resin transfer molding (RTM), sometimes
called liquid molding, is a closed-molding
method in which reinforcement material is
loaded into a closed mold, the mold is
clamped, and resin is pumped in (through
injection ports) under pressure. This
process produces complex parts with
smooth finishes on all exposed surfaces. The
process can be simple or highly
automated–and cycle times are speedy. By
laying up reinforcement material dry inside
the mold, any combination of materials and
orientation can be used, including 3-D
reinforcements.
COMPRESSION Compression molding is a

MOLDING
manufacturing process in which
composite materials are sandwiched
between two matching molds under
intense pressure and heat (from 250°
to 400° F) until the part cures. This
technique is used to rapidly cure large
quantities of complex fiberglass-
reinforced polymer parts.
Compression molding features fast
molding cycles and high part
uniformity. The process can be
automated. In addition, labor costs are
low and it provides design flexibility
and nice surface finishes.
PULTRUSION
Pultrusion is used to form composites into
long, consistent shapes like rods or bars.
Continuous strands of reinforcement are
pulled through a resin bath to saturate them,
then pulled through heated steel molds that
sculpt the composites into continuous
lengths. The process operates continuously
so it can be readily automated. Labor costs
are low and finished products are very
strong. Pultrusion is used to make products
such as beams, channels, pipes, tubing,
fishing rods and golf club shafts.

LEARN MORE
REINFORCED
REACTION
INJECTION
Reinforced reaction injection molding (RRIM) is widely
used to make external and internal automotive parts.
In this process, two (or more) resins are heated
separately and combined with milled glass fibers. The
mixture is injected into a mold under high pressure and
compressed. The resin cures quickly. RRIM composites
feature many processing advantages, including very
fast cycle time, low labor, low mold-clamping pressure
and low scrap rate. The RRIM process requires special
resins and reinforcements.
 CENTRIFUGAL
CASTING
In centrifugal casting, reinforcements and
resin are deposited against the inside
surface of a rotating mold. Centrifugal
force holds them in place until the
material cures or hardens. Centrifugal
casting is used to produce hollow parts
(like pipes with two smooth surfaces). It’s
especially well-suited for producing
structures with large diameters, such as
pipes for oil and chemical industry
installations and chemical storage tanks.
Centrifugal casting is increasingly being
used to produce telephone, street light
and other poles.
 CONTINUOUS
LAMINATION
Continuous lamination is used to make flat or corrugated
sheets and panels for products used in truck and RV
sidewalls, road signs, skylights, building panels and
electrical insulating materials. It’s a highly automated
process in which fibers and resin are combined,
sandwiched between two plastic carrier films—and
guided through a conveyor process. Forming rollers
shape the sheets, and the resin is cured (in an oven or
heating zone) to form the composite panel. Panels are
automatically trimmed to the desired width and length.
CAST
POLYMER
MOLDING
Cast polymers are unique in the composites
industry: they typically don’t have fiber
reinforcement and are designed to meet specific
strength requirements of an application. Cast
polymer molding is used to produce parts of any
shape or size.
 GEL COAT
Gel coat is a specialized polyester resin that is formulated
to provide a cosmetic outer surface on a composite
product and to provide weatherability for outdoor
products. Several variations of cultured stone products
are manufactured using a gel coated surface and a resin-
matrix casting process. In this process a gel coat film
(usually clear) is sprayed on the mold surface. Once the
gel coat is sufficiently cured, a polyester resin matrix is
blended by adding various types of fillers to the resin.
Pigments for both a solid background color and the look
of veins found in natural stone can be added. The resin
matrix is then transferred to the mold, where vibration is
applied to level and compact the matrix. Following the
cure, the part is removed from the mold.
SOLID SURFACE
MOLDING
Solid surface products (also known as
densified products) consist of a cast matrix
without a gel-coated surface. A vacuum can
be used to remove entrapped air in the
matrix. Solid surface products offer limitless
design styles. Solid surface can be
formulated to achieve a wide variety of looks
and cosmetic effects, such as simulating
natural granite stone. For this reason, it is
often used to manufacture products like
kitchen countertops.
LEARN MORE
 KINDS AN D TY PE S
P LES O F CO MP OS ITES
EXAM
These types of composites cover a
range of different material
combinations.
PAGE
01 POLYMER MATRIX
COMPOSITES
(PMCS)
Polymer-matrix composites are the most common;
they may be reinforced with glass,
carbon, and aramid fibers.
METAL MATRIX
PAGE
02

COMPOSITES
(MMCS)
Materials produced by adding
reinforcement in the form of particles
(ceramic or metal), fibers, whiskers, or
even a sheet metal to a metal or alloy
matrix.
CERAMIC- PAGE

MATRIX
03

COMPOSITES
A special type of composite
material in which both the
reinforcement (refractory fibers)
and the matrix material are
ceramics
PAGE
CARBON–
CARBON
05

COMPOSITES
• Carbon-carbon composites are composed of
carbon fibers embedded in a pyrolyzed
carbon matrix.
• These materials are expensive and used in
applications requiring high strengths and
stiffnesses (that are retained at elevated
temperatures), resistance to creep, and good
fracture toughnesses.
HYBRID
PAGE
06

COMPOSITES
The hybrid composites contain at least two
different fiber types. By using hybrids, it
is possible to design composites having
better all-around sets of properties.
 PAGE
07

PROCESSING OF
FIBER-REINFORCED
COMPOSITES
Fiber-reinforced polymers (FRPs) are a type of
composite plastics made of a matrix or binding
agent reinforced by a fiber material. The FRP
process thus entails two steps: making the fibrous
material and bonding the material with a polymer
plastic.
STRUCTURAL
PAGE
08

COMPOSITES
A structural composite is a multi-layered
and normally low-density composite used in
applications requiring structural integrity,
ordinarily high tensile, compressive, and
torsional strengths, and stiffnesses. The
properties of these composites depend not.
 TWO GENERAL KINDS OF STRUCTURAL COMPOSITES

LAMINAR COMPOSITES
composed of a set of two-
dimensional sheets that are bonded
to one another; each sheet has a
high-strength direction.

SANDWICH PANELS
PAGE consist of two strong and stiff sheet faces that are
09 separated by a
core material or structure. These structures combine
relatively high strengths and
stiffnesses with low densities.
 NANOCOM
PAGE
10

POSITES
• Nanocomposites—nanomaterials embedded in a
matrix (most often a polymer)—use
the unusual properties of nanosized particles.
• Nanoparticle types include nanocarbons,
nanoclays, and particulate nanocrystals.
• Uniform and homogeneous distribution of
nanoparticles within the matrix is the
major production challenge for nanocomposites.
 Composite materials are used in a wide range of
applications due to their unique combination of
properties, such as high strength, low weight, and
resistance to corrosion.
 AEROSPACE

Composite materials are extensively

used in the aerospace industry for
their high strength-to-weight ratio.
Com po si te m at er ia ls ha ve be en us ed
in ae ro sp ac e in ap pl ic at io ns su ch as
engine bl ad es , br ac ke ts , in te ri or s,
nacelles, propellers/rotors, single aisle
wings, and wide-body wings.
 AUTOMOTIVE
Composite materials are used in the
manufacturing of car bodies,
especially for high-performance
vehicles. They are also used in the
construction of racing car bodies
and parts.
 SPORTS
Com po si te m at er ia ls ar e w id el y us ed
in sports equipment such as golf
clubs, tennis rackets, and bicycle
frames, due to their strength,
lightness, and flexibility.
 CONSTRUCTION
Com po si te m at er ia ls ar e us ed in th e
construction industry for their high
strength and durability. They are
used to make building panels, bridge
decks, and reinforcement bars.
 MARINE
Composite materials are used in the
construction of boats and ships due
to th ei r hi gh st re ng th , re si st an ce to
corrosion, and low weight.
 MEDICAL
Composite materials are used in the
manufacturing of prosthetics,
or th ot ic s, an d im pl an ts du e to th ei r
biocompatibility and strength.
 ELECTRONICS
Com po si te m at er ia ls ar e us ed in th e
manufacturing of electronic devices
such as printed circuit boards and
microchips, due to their excellent
electrical and thermal conductivity.
 ENERGY
Com po si te m at er ia ls ar e us ed in th e
wind energy industry for the
manufacturing of wind turbine
blades, due to their high strength
an d lo w w ei gh t. Th ey ar e al so us ed
in th e co ns tr uc ti on of oi l an d ga s
pipelines for their corrosion
resistance.
 GROUP 3- COMPOSITES

MAGNAYE, CRIS PAUL

REPORTER LAGUARDIA, ALLYSA

VILLAREAL, ISAAC MIGUEL DIAZ, JOHN ALFRED

MENDOZA, CARLIN JOSH GASANGUE, DIANA MARIE