Composite Materials

1. University of Engineering and Technology,
Peshawar
Materials Engineering Department
Presented By:
Mohsin Ali Marwat
Presented To:
Dr. Rizwan Gul

2. Contents
• Introduction
• General Properties and Microstructure
• Classifications
• Processing Methods
• Applications
• Trade Names
• Availability in Pakistan

3. Definition
A materials system composed of a mixture or combination
of two or more micro or macro- constituents that differ in
form and chemical composition and are essentially
insoluble in each other.
General Properties:
•High Strength-to-weight ratio
•Corrosion Resistance
•Wear Resistance
•Greater fatigue Life
•Low electrical conductivity
•Anisotropic
•Lower cost
•Easy processing
•Covers almost all application areas
Composite
Materials
Introduction

4. Factors affecting Microstructure and properties of
composites
• Type of Reinforcement
• Reinforcement size and its Orientation
• Matrix Type
• Fiber-Volume-Fraction (FVF)
• Direction of loading
• Bonding between Reinforcement and matrix
Introduction
Composite
Materials

5. Classification
1. On the basis of Reinforcement
– Size:
Composites
Particulate Fiber Laminate
– Type of Fibers:
• Aramid
• Glass
• Carbon
2. On the basis of matrix
– PMC
– MMC
– CMC
Classification
Composite
Materials

6. • Particulates:
– Equal sized, spherical reinforcement material
– Imparts least anisotropic property to composite
• Fibers:
– Long relative to particulates
• Laminates:
– Layer-by-layer Structure
– Honey Comb Structure (HCS)
• Honey comb cells are filled with flexible material.
• Higher strength, Stiffness along the columnar side
(Upside) of the HCS.
• Lower strength when pressed from sides.
Figure: Honey Comb Structure
Classification
Reinforcement

7. Metal Matrix Composites (MMC)
Material having Metal as a matrix material in
composites is called a Metal matrix composite.
•High Tensile Strength
•High Specific Gravity
•High Toughness (For Large diameter Fiber)
•High Creep Resistance
•High Elastic Modulus
•Examples:
– Boron/Aluminum Composite
– SiC/Aluminum Composite
Classification
Matrix
Materials

8. MMCClassification
Matrix
Materials

9. Diffusion BondingClassification
Matrix
Materials

10. Ceramic Matrix Composites
Material having Ceramic as a matrix material in
composites is called a ceramic matrix composite.
Properties:
•High strength
•Hardness
•High service temperature
•Chemical inertness
•Low density
Matrix SiC Whisker
Content (Vol%)
Flexural
Strength (MPa)
Fracture
Toughness
(Mpa/(m)½
Si3N4 0 400-650 5-7
10 400-500 6.5-9.5
30 350-450 7.5-10
Al2O3 0 ------ 4.5
10 400-510 7.1
20 520-790 7.5-9.0
Source: “Engineered Materials Handbook”, Vol 1, Composite, ASM, 1987
Classification
Matrix
Materials

11.  80-85% Alumina
 5-10% Carbon Nanotubes
 5% finely Milled Niobium Sintered and Densified
Properties:
 High Fracture Strengths i.e. Five times greater than
Alumina
 Ten trillion times greater conduction of Electricity than
pure alumina
 Conducts heat if C fibers are oriented parallel to the heat
flow
 Insulate heat if C fibers are oriented perpendicular to the
heat flow
Ceramic Matrix Composite and NanotechnologyCeramic Matrix Composite and NanotechnologyClassification
Matrix
Materials

12. Polymer Matrix Composites
Material having Polymer as a matrix material in
composites is called a Polymer matrix
composite.
Properties
•Ease of Fabrication
•Lower cost
•Polymer phase increases
– Elastic Modulus
– Yield Strength
– Tensile Strength
– Creep Resistance
Classification
Matrix
Materials

13. – Simplest method
– Multiple layering for achieving desired
thickness
– Hand roller is used for
• Compaction of the structure
• Removal of air bubbles
– Applications: Boat hulls, tanks, housing and
building panels
1. Hand Lay-UpProcessing
Methods

14. – Combination of Chopper and Spray Gun
– Catalyzed resin + chopped fibers Spray
– Multiple layering for achieving desired thickness
2. Spray-Up Process:Processing
Methods

15. 3. Filament Winding
Resin bath
Roving guideRoving or tow
package
Rotating
Mandrel
 Continuous technique
 Band of fibers
 Successive layering
 Seven axis of rotations
 Increasing tension on bands
 Applications: cylindrical products
 Lowering resin viscosity
Processing
Methods

16. 4. Vacuum Bagging
• Placing fabric into the mold
• Making it airtight by Polyethylene bag
• Adding resin inside
• Resin spreads
• Impregnates the fibers
Processing
Methods

17. 5. Prepreg
• Fibers + partially cured Resin
• Available in the form of tapes
• Easy to apply
Processing
Methods

18. 6. Compression Molding
• Charge: uncured resin and fibers
• Mold: Tool Steel
• Placing the charge into the mold cavity
• Closing the mold and compressing the charge
• Charge uniformly fills the mold cavity
• Charge is heated under pressure for curing
Processing
Methods

19. 7. Pultrusion
• Pull + Extrusion
• Fibers are impregnate with resin
• Preheating of fibers
• pulled through a heated Die (Extrusion)
• Curing in “Curing Die”
Processing
Methods

20. 8. Sheet Molding Compound (SMC)
• Spreading resin and filler paste on a carrier film
• Sprinkling Chopped fibers
• Spreading another resin and filler paste layer
• Compacting and removing air entrapped via compact
mills
• Storing on the Take-Up Roll
Processing
Methods

21. Applications

22. Trade Names
Manufacturer:
– CYTEC
– Automative Armor Manufacturer (AAM)
– 3Tex Inc. (3d fiber designing)
– Avanced Carbon Technology Inc.
– Dupont
– Bayliner (GFRP Boats)
Product Trade Names:
– TEAM V (GFRP Boats)
– Nomex (Solid Surfaces)
– CORIAN (THERMAL PROTECTIVE FIBERS)
– PRO V II (GFRP Boats)
– DANISCO (FOOD BEVERAGES)
– KEVLAR
– TYVEK (CONSTRUCTION INDUSTRY)

23. Availability in Pakistan
• Sami Fiber Glass
• Fiber Master
• Industrial Techno International
• Matrix Private Limited
• Pioneer Fiber Glass
• Mianjee Fiber Glass Work
• Institutes (providing facility composite Works)
– PIEAS
– IST
– NUST
– GIKI
– UET Lahore