Composite Material Defined • A materials system composed of two or more physically distinct phases whose combination produces aggregate properties that are different from those of its constituents Advantages • Composites can be very strong and stiff, yet very light in weight, so ratios of strength- to-weight and stiffness-to- weight are several times greater than steel or aluminum • Fatigue properties are generally better than for common engineering metals • Toughness is often greater too • Composites can be designed that do not corrode like steel • Possible to achieve combinations of properties not attainable with metals, ceramics, or polymers alone Components in a Composite Material Nearly all composite materials consist of two phases: • 1. Primary phase - forms the matrix within which the secondary phase is imbedded • 2. Secondary phase - imbedded phase sometimes referred to as a reinforcing agent, because it usually serves to strengthen the composite The reinforcing phase may be in the form of fibers,particles, or various other geometries Classification Scheme for Composite Materials 1. Metal Matrix Composites (MMC) - mixtures of ceramics and metals, such as cemented carbides and other cermets 2. Ceramic Matrix Composites (CMC) – Al2O3 and SiC imbedded with fibers to improve properties, especially in high temperature applications The least common composite matrix 3. Polymer Matrix Composites (PMC) - thermosetting resins are widely used in PMC Examples: epoxy and polyester with fiber reinforcement,and phenolic with powders Functions of the Matrix Material(Primary Phase) Provides the bulk form of the part or product made of the composite material Holds the imbedded phase in place, usually enclosing and often concealing it When a load is applied, the matrix shares the load with the secondary phase, in some cases deforming so that the stress is essentially born by the reinforcing agent The Reinforcing Phase (Secondary Phase) • Function is to reinforce the primary phase 1
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Composite Material Defined
• A materials system composed of two or more physically distinct phases whose combination produces aggregate properties that are different from those of its constituents
Advantages
• Composites can be very strong and stiff, yet very light in weight, so ratios of strength-to-weight and stiffness-to-weight are several times greater than steel or aluminum
• Fatigue properties are generally better than for common engineering metals
• Toughness is often greater too
• Composites can be designed that do not corrode like steel
• Possible to achieve combinations of properties not attainable with metals, ceramics, or polymers alone
Components in a Composite Material Nearly all composite materials consist of two phases:
• 1. Primary phase - forms the matrix within which the secondary phase is imbedded
• 2. Secondary phase - imbedded phase sometimes
referred to as a reinforcing agent, because it usually serves to strengthen the composite
The reinforcing phase may be in the form of fibers,particles, or various other geometries
Classification Scheme for Composite Materials
1. Metal Matrix Composites (MMC) - mixtures of ceramics and metals, such as cemented carbides and other cermets
2. Ceramic Matrix Composites (CMC) – Al2O3 and SiC imbedded with fibers to improve properties, especially in high temperature applications
The least common composite matrix
3. Polymer Matrix Composites (PMC) - thermosetting resins are widely used in PMC Examples: epoxy and polyester with fiber reinforcement,and phenolic with powders
Functions of the Matrix Material(Primary Phase)
Provides the bulk form of the part or product made of the composite material
Holds the imbedded phase in place, usually enclosing and often concealing it
When a load is applied, the matrix shares the load with the secondary phase, in some cases deforming so that the stress is essentially born by the reinforcing agent
The Reinforcing Phase (Secondary Phase)
• Function is to reinforce the primary phase
• Imbedded phase is most commonly one of the following shapes:
Fibers
Particles
Flakes
• In addition, the secondary phase can take the form of an infiltrated phase in a skeletal or porous matrix
Example: a powder metallurgy part infiltrated with polymer
Fibers
Filaments of reinforcing material, usually circular incross-section
Diameters range from less than 0.0025 mm to about 0.13 mm, depending on material
Filaments provide greatest opportunity for strength enhancement of composites
1
The filament form of most materials is significantly stronger than the bulk form
As diameter is reduced, the material becomes oriented in the fiber axis direction and probability of defects in the structure decreases significantly
Continuous vs. Discontinuous Fibers
Continuous fibers - very long; in theory, they offer a continuous path by which a load can be carried by the composite part
Discontinuous fibers (chopped sections of continuous fibers) short lengths (L/D = roughly 100)
Important type of discontinuous fiber are whiskers –hair like single crystals with diameters down to about 0.001 mm (0.00004 in.) with very high strength
Fiber Orientation – Three Cases
One-dimensional reinforcement, in which maximum strength and stiffness are obtained in the direction of the fiber
Planar reinforcement, in some cases in the form of a two-dimensional woven fabric
Random or three-dimensional in which the composite
material tends to possess isotropic properties
Particles and Flakes
A second common shape of imbedded phase is particulate, ranging in size from microscopic to macroscopic
Flakes are basically two-dimensional particles - small flat platelets
The distribution of particles in the composite matrix is random, and therefore strength and
other properties of the composite material are usually isotropic
Strengthening mechanism depends on particle size
The Interface
There is always an interface between constituent phases in a composite material
For the composite to operate effectively, the phases must bond where they join at the interface
Interphase
In some cases, a third ingredient must be added to achieve bonding of primary and secondary phases
Called an interphase, this third ingredient can be thought of as an adhesive
Properties are Determined by Three Factors:
1. The materials used as component phases in the composite
2. The geometric shapes of the constituents and resulting structure of the composite system
3. The manner in which the phases interact with one another
2
Computing composite properties
Determine the mechanical property of Continuous and Aligned Fiber composites
Longitudinal direction
Fc =Fm + Ff
The assumption of an isostrain state :
The ratio of the load carried by the fibers to that carried by the matrix is
Transverse Loading
The assumption of an isostress state :
Determine the mechanical property of Discontinuous and Aligned Fiber Composites
If the fiber length (l) is less than critical(lc), the longitudinal strength
If (l >lc), the longitudinal strength
Where
Determine the mechanical property of Discontinuous and Randomly Oriented Fiber Composites
Where K = fiber efficiency parameter
3
= 0.1 -0.6.
EXAMPLE PROBLEM
A continuous and aligned glass fiber-reinforced composite consists of 40 vol% of glass fibers having a modulus of elasticity of 69 GPa and 60 vol% of a polyester resin that, when hardened, displays a modulus of 3.4 GPa.
(a) Compute the modulus of elasticity of this composite in the longitudinaldirection.
(b) If the cross-sectional area is 250 mm2 and a stress of 50 MPa is applied in this longitudinal direction, compute the magnitude of the load carried by each of the fiber and matrix phases.
(c) Determine the strain that is sustained by each phase when the stress inpart (b) is applied.
Polymer Matrix Composites (PMCs)
A polymer primary phase in which a secondary phase is
imbedded as fibers, particles, or flakes
Commercially, PMCs are more important than MMCs or CMCs
Examples: most plastic molding compounds, rubber reinforced with carbon black, and fiber-reinforced polymers (FRPs)
Fiber-Reinforced Polymers (FRPs)
A PMC consisting of a polymer matrix imbedded with high-strength fibers
Polymer matrix materials:
Usually a thermosetting (TS) plastic such as unsaturated polyester or epoxy
Can also be thermoplastic (TP), such as nylons (polyamides), polycarbonate, polystyrene, and polyvinylchloride
Fiber reinforcement is widely used in rubber products such
as tires and conveyor belts
Fibers in PMCs
Various forms: discontinuous (chopped), continuous, or woven as a fabric
Principal fiber materials in FRPs are glass, carbon, and Kevlar 49
Less common fibers include boron, SiC, and Al2O3, and steel
Glass (in particular E-glass) is the most common fiber material in today's FRPs;
Metal Matrix Composites (MMCs)
A metal matrix reinforced by a second phase
Reinforcing phases:
1. Particles of ceramic (these MMCs are commonly called
cermets)
2. Fibers of various materials: other metals, ceramics, carbon, and boron
Cemented Carbides
One or more carbide compounds bonded in a metallic matrix
Common cemented carbides are based on tungsten carbide(WC), titanium carbide (TiC), and chromium carbide(Cr3C2)
Tantalum carbide (TaC) and others are less common
Metallic binders: usually cobalt (Co) or nickel (Ni)
Ceramic Matrix Composites (CMCs)
A ceramic primary phase imbedded with a secondary phase, which usually consists of fibers
Attractive properties of ceramics: high stiffness, hardness, hot hardness, and compressive strength; and relatively low density
Weaknesses of ceramics: low toughness and bulk tensilestrength, susceptibility to thermal cracking
CMCs represent an attempt to retain the desirable properties of ceramics while compensating for their weaknesses