Engineering Composite Materials

(MatE 6314)
Introduction to Composite and Classification

Dawit Gemechu (Ph. D.)

E-mail: dawit.gemechu@aait.edu.et
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Engineering Materials
 The evolution of Engineering Materials with time

Evolution and relevance of materials in the human history

Michael F. Ashby, “Materials selection in mechanical design. 4th Edition - Elsevier (2010)
 Composite Materials: Definitions
 Two or more materials, macroscopically different in aspect (morphology), whose
combination produces a new material with new properties (mechanical, magnetic,
electrical, thermal, optical, etc.) that depend on the constituent properties

 Composite materials are like sandwiches. A good sandwich contains a variety of

ingredients to yield a taste that no single ingredient could provide by itself

 Similarly, composite materials are those which are formed from two or more
materials producing properties or characteristics that could not be obtained from any
one material
Considering mechanical reinforcement of the aimed
composites:

Composites consist of one or more discontinuous phases

embedded in a continuous phase.

The discontinuous phase is usually harder and stronger

than the continuous phase and is called the reinforcement
or reinforcing material, whereas the continuous phase is
termed the matrix.
 Composite Materials
Are Composite materials new?
Already thousands of years ago mud and straw were combined to make bricks that have
been used to build houses, monuments and towns.

Thanks to the presence of the straw, the mud does not cracks during desiccation and
contributes to a brick with improved mechanical properties,
 Composite Materials
Are Composites materials new?

The word 'composites' has a modern ring

But using the high strength of fibers to stiffen and strengthen a cheap
matrix material is probably older than the wheel. ...

Almost all natural materials which must bear load--wood, bone, muscle-
are composites. ...

The composite industry, however, is new. It has grown rapidly in the past
30 years with the development of fibrous composites...
 Composite Materials
Are Composites materials new?
Examples of Composites materials
 Straw-bricks
 Concrete (cement + gravel)
 Wood (cellulose + lignin)
 Human body (muscles + bones)
 Tires
 Transportation
 Plywood
 Sports good …
 Composite Materials - Outlines
 Introduction: Definition and characteristics of composite
 Composite materials: composites in nature and beyond, applications...
 Classification: according to type of matrix and reinforcement

 Metal Matrix Composites (MMC)  Particulate Composites

 Ceramic Matrix Composites (CMC)  Fibrous Composites
 Polymer Matrix Composites (PMC)  Structural Composites
 Hybrid Composites
 Particle reinforced composite materials
 Fiber reinforced composite materials: types of fibers
 Structural composite materials (laminates and sandwich structures)
 Fiber-Matrix Adhesion : Interphase and Interface
 Composite micromechanics and mechanics theory
 Applications and fabrication techniques of composite materials
 Case studies and design project
 Composite Materials
Classification of composites
Composite material: a material composed of two or more distinct phases
(matrix phase + dispersed phase) and having bulk properties significantly
different form those of any of the constituents

Design goal: obtain a more desirable combination of properties

Matrix
Composite to develop optimum combinations
Reinforcement
Matrix phase
 The primary phase, having a continuous phase/character
 Matrix is usually more ductile and less hard phase
 It holds the dispersed phase and shares a load with it
 Embeds, surrounds, and supports the reinforcements
Dispersed (reinforcing) phase
 The second phase/phases embedded in the matrix in a discontinuous form
 Usually stronger than the matrix, therefore it is called reinforcing phase
 Composite Materials
Matrix Phase: Functions
 Holds the fibers together
 Protects the fibers from environment
 Protects the fibers from abrasion (with each other)
 Helps to maintain the distribution of fibers
 Transmit force between fibers
 Distributes the loads evenly between fibers
 Arrest cracks from spreading between fibers
 Holds fibers in proper orientation
 Enhances some of the properties of the resulting material and
structural component (that fiber alone is not able to impart)
 Composite Materials
Reinforcement Phase: Functions

 Contribute desired properties

 Load carrying
 Transfer the strength to matrix
 Composite Materials
Classification of composites based on Matrix materials
MMC, CMC, PMC
 Metal Matrix Composites (MMC)
 Ceramic Matrix Composites (CMC)
 Polymer Matrix Composites (PMC)

1. Metal Matrix Composites (MMC)

 Composed of a metallic matrix (Al, Mg, Fe, Co, Cu) and a dispersed
ceramic (oxides, carbides) or metallic (Pb, W, Mo) phase

 fibers or particles surrounded by a matrix of metal;

 the matrix is a ductile metal
 the reinforcement improve specific stiffness, strength, abrasion
resistance, creep resistance, thermal conductivity, and stability
 Composite Materials
….Metal Matrix Composites (MMC)…
 The matrix materials: super-alloys, alloys of Al, Mg, Ti, and Cu,
 Reinforcement: in the form of particulates, both continuous and
discontinuous fibers, and whiskers

 Continuous fiber: include C, SiC, B, Al2O3, and the refractory metals

 Discontinuous reinforcements: consist primarily of SiC whiskers,
chopped fibers of Al2O3 and C, and particulates of SiC and Al2O3

 Processing of MMC: synthesis (i.e., introduction of reinforcement

into the matrix), followed by a shaping (forging, extrusion, rolling…)

 Applications: Automobile, aerospace industry, …

 Higher operating T,
 But much more expensive than PMCs
 Composite Materials
2. Ceramic Matrix Composites (CMC)
 Composed of a ceramic matrix and embedded fibers of other ceramic material

(dispersed phase)

 When particulates, fibers, or whiskers of one ceramic material embedded into a

matrix of another ceramic

 CMCs are non - brittle refractory materials designed for applications in severe

environments (often combining high T, high stress levels and corrosive atm.)

 CMC materials have extended fracture toughness results from interactions

between advancing cracks and dispersed phase particles

Walter Krenkel,‘Ceramic Matrix Composites: Fiber Reinforced Ceramics and their Applications’, 2008 Wiley‐VCH Verlag GmbH & Co. KGaA
 Composite Materials
3. Polymer Matrix Composites (PMC)
 Consisting of a polymer (resin) matrix combined with a fibrous reinforcing dispersed phase
 Provides strength and stiffness that are lacking in the matrix
 Composed of a matrix from thermoset (Unsaturated Polyester (UP), Epoxy (EP)) or
thermoplastic (PC), PVC, Nylon, PS); and embedded glass, carbon, steel or Kevlar fibers
(dispersed phase)

Assignment 1 (5%): Prepare a 2 pages review/report on: Monomer, Polymer; Polymerization;

linear, branched, cross-linked polymers; thermosetting & thermoplastic polymers; elastomers

! Please do it neatly! Avoid any kind of copy-paste

 Composite Materials
…Polymer & Polymer Matrix Composites (PMC)…
Polymer: a large molecule (macromolecule) composed of repeating structural units
(monomer) connected by covalent chemical bonds
 Composite Materials
…Polymer Matrix Composites (PMC)…
 PMCs are very popular due to their low cost and simple fabrication methods
 Reinforcement of polymers by strong fibrous network permits fabrication of PMC
characterized by the following properties:

 High tensile strength;  Good abrasion resistance;

 High stiffness;  Good corrosion resistance;
 High Fracture Toughness;  Low cost

 According to the reinforcement material the following groups of PMC are used:
Fiber glasses – Glass Fiber Reinforced Polymers;
Carbon Fiber Reinforced Polymer Composites;
Kevlar (aramid) fiber reinforced polymers.
 Composite Materials
Classification of composites based on reinforcement materials
Some composites involve fibers, while others rely on particles, including elongated particles
(whiskers) and flat particles (flakes)
 Particulate Composites
 Fibrous Composites
 Structural Composites
 Composite Materials
Classification of composites based on reinforcement materials

1. Particulate-Reinforced Composites
Consists of matrix reinforced by a dispersed phase in form of particles
 Composites with random orientation of particles
 Composites with preferred orientation of particles.

Sub-classifications of particle-reinforced composites

 large-particle composite The distinction is based upon
 dispersion-strengthened composites reinforcement or strengthening mechanism

 Metals and metal alloys strengthened and

hardened by the uniform dispersion fine
particles (metallic, non-metallic, oxides…)
e.g. Al-Al2O3 system
 Composite Materials
Examples of Particulate Reinforced Composites

Randall M. German, Particulate Composites Fundamentals and Applications

 Composite Materials
Classification of composites based on reinforcement materials
2. Fibrous -Reinforced Composites
1. Short-fiber reinforced composites: a matrix
reinforced by a dispersed phase in form of
discontinuous fibers

 Composites with random orientation of fibers

 Composites with preferred orientation of
fibers

2. Long-fiber reinforced composites: dispersed

phase in form of continuous fibers

 Unidirectional orientation of fibers

 Bidirectional orientation of fibers (woven)
 Continuous and aligned,
 Discontinuous and aligned, and
 Discontinuous and randomly oriented
 Composite Materials
Classification of composites based on reinforcement materials
3. Structural Composites
 Composed of both homogeneous and composite materials,
 The properties depend on the properties of the constituent materials and geometrical
design of the structural elements

 laminated composites
Two types :
 sandwich structures
 Composite Materials
3. Structural Composites…
1. Laminate-Reinforced CompositesLaminar composite
 material layers stacked together by the matrix;
 2D sheets or panels that have a preferred high-strength direction
 Orientations: combined (0, 90, +/-45o) to achieve the desired strength & stiffness
 The strength and stiffness varies greatly with the orientation
 Composite Materials
Structural Composites
2. Sandwich Composites---sandwich panels
Consists of two outer sheets/faces separated by and bonded to a thicker core

 made of a relatively stiff & strong material,

typically Al alloys, fiber-reinforced plastics,
Ti, steel, or plywood; they impart high core
stiffness and strength to the structure

 must be thick enough to withstand tensile

and compressive stresses result from loading

 The core material is lightweight, and has a

low modulus of elasticity

 Core materials fall within either rigid

polymeric foams (i.e., phenolics, epoxy,
polyurethanes), wood, and honeycombs

 It provides continuous support for the faces

 Composite Materials
Hybrid Composites
 Obtained by using two or more different kinds of fibers in a single matrix;
 Have a better all around combination of properties than composites
containing only a single fiber type
E.g.: carbon fiber and glass fibers incorporated into a polymeric resin

 Are strong and relatively stiff and

 are inexpensive
 Provide a low-density reinforcement;
 lack the stiffness of carbon
 However, they are expensive

 The hybrid is stronger and tougher,

 Has a higher impact resistance, and
 may be produced at a lower cost