Introduction to Composite

Created by Prof Deeksha Tiwari

Introduction

Composites are engineered materials, comprising of metals, ceramics,

glasses and polymers. The relationship between these three

constitutes with respective examples is shown in Fig below.

 Ceramics or
glasses
E.g. silicates etc

Carbon fibre
reinforced polymer
Cements Composites (CFRP)
Glass fibre
reinforced
polymer (GFRP)

Metals or Steel Polymers

their alloys cord Or
E.g. steels Tires elastomers

Engineering materials forming composites

• Composites obtained using respective material exhibits unique properties or qualities.

• Composites show better characteristics as compared to those possessed by its

constituents

• Sometimes all together new / different characteristic is observed to be possessed by

composite material which present in either of its constituents.

• Combination of two or more existing materials is brought about by physic pal means. A

composite in true sense must show matrix material surrounding its reinforcing material

completely, in which the two phases , not only exist , but act together so as to produce the

desired characteristics.
Examples

❑ Wood or many other plant tissues contain cellulose chain polymer in a matrix of lignin.

❑ Bone which contain soft but strong protein collagen and hard and brittle material apatite.

SYNTHETIC COMPOSITE SUCH AS

• Rain proof cloth (cloth impregnated with waterproof material)

• Packing paper impregnated with bitumen or wax,

• Reinforced concrete

• Insulating tape
DEFINTION
A multiphase product made by using two or more existing materials which exhibit properties of its
constituents as well as shown certain unique properties of its own.

The properties of composite solely depend upon the composition of its constituents.

DAIGRAM
The constituent of composite materials include phases commonly called as matrix

phase and second phase is embedded in the matrix is known as dispersed phase.

The boundary between the matrix and dispersed phase are known as interface.

DAIGRAM
CHARACTERISTICS
• It has excellent corrosion resistance property.

• Most importantly ,composites are lightweight and easy to handle.

• It has good abrasion resistance.

• It provides high mechanical strength along the direction of their reinforcements.

• It is comprised of high stiffness.

• It provides good electrical and thermal insulation .

• It offers ease of shaping and economic mass production.

CONSTITUENTS OF COMPOSITES

Matrix phase: Polymeric materials act as matrix phase in the composite .it bind the reinforcing
materials strongly. It acts as medium for distribution of reinforcing particles which keeps them in proper
orientation. It also prevents the crack due to plasticity. E.g: Resins.

Dispersed phase : The substances embedded on the matrix phase are known as dispersed phase.
These are mainly two types, fibres and particle.

FIBRES

(a) Glass fibres: The glass fibres are produced by passing a glass melt through small orifices
(holes) and cooled .Glass fibres are popular reinforcing materials .It offers very high tensile
strength, highest thermal stability, high toughness and impact strength to the polymer matrix.
Polymers are filled with 20% to 40% glass fibres.
(b)Carbon fibres: they are prepared from carbon by oxidation under tension at low
temperature and then carbonization at 1000℃ .These fibres are stiff ,strong even at high
temperature.

(c)Aramid fibres: Aramid is the aromatic polyamide eg: Nomex, Kevlar .it has liquid crystals
polymer property. Its parallel arranged polymer chains for a long distance can be obtained
from melt during drawing .The fibres have very high tensile strength ,impact resistance ,high
thermal stability.

(d)Silicon carbide fibres

(e) Aluminium oxide fibers

(f) Metal wires

PARTICLES
Metal powders ,metal oxides, carbon black, metal carbides ,silica powder, mica, salts can be
intimately mixed with the polymer matrix to make the composite.

These materials offer high abrasion resistance ,higher mechanical strength better performance at
higher temperature to the composite and may modify thermal and electrical conductivity of polymer.

Function of matrix phases

• It binds the reinforcing particles.

• It act as medium of applied load to the dispersed phase.

• It keeps the reinforcing fibers in proper orientation for the high strength development.

• It prevents propagation of cracks due to its plasticity.

 CLASSIFICATION OF COMPOSITES
The composites are classified on the basis of reinforcing material or structure as follows :

Composites

On the basis of reinforcing On the basis of

material structure

Particle reinforced Fibre reinforced Structural

composites composites composites

Large- Dispersion- Continuous Discontinuous Sandwich

Laminates
particle strengthened (long) aligned (short) panels
composites Composites

Aligned Random
Particle-reinforced Composites
In this type of composites, the size of particles in dispersed phase are of nearly the same in all direction.
Large particle composites
In this sub-type of composites, the particulate phase should have following characteristics.
a) Stiffer and harder as compared to matrix phase.
b) It acts as reinforcing material.
c) It restrains the movement of matrix surrounding to itself.
d) The bond strength between two phase governs mechanical properties of composite.

Table : Examples of particle reinforced composites

Material Matrix phase Particulate phase Properties
1. Concrete Cement Sand and gravels 1. R.c.c is harder than
ordinary cement.
2. Sets well on surface
thereby holding structures.
2. Cermet's Cr Al2O3 1. Good strength.
2. Very good thermal shock
(a) Oxide based resistance.
 Material Matrix phase Particulate phase Properties
(b) Carbide based Co or Ni Tungsten Carbide 1. Very hard
(WC) 2. Very high surface
hardness
Or
Application: In wire
Titanium carbide drawing dyes, valves
(TiC) and machine parts.
Co or Ni Or
Chromium carbide High abrasion and
(CrC) corrosion resistance

Application: In valves,
spray nozzle pump
parts etc.
Dispersion-strengthened composites
• In this type of composite, the particles size is smaller (10 to 100 nm).

• The metal or alloys are made into extremely small particle size in given range and
are dispersed in the matrix phase. This is achieved by appropriate heat treatment.
The process is called as “precipitation hardening” or “Age hardening”, the former
term given because the new phase of materials obtained in process is know as
“precipitates”, where as latter term is suitable because composite increase its
hardness as alloy ages.

e.g. Alloys such as, Cu – Sn, Mg – Al, Cu – Be, Al-Cu, some ferrous alloys are
hardnened and made into composite materials with ceramics.
Flakes
• Description: Thin solids with two-dimensional geometry.
• Usage: Used as reinforcements in matrices. Typical flake materials include
glass, mica, aluminum, and silver.

Whiskers
• Definition: Whiskers are single crystal fibers, often used for their high
strength.
• Characteristics: Thin and strong filaments made by growing crystals. Whiskers
are used as fiber reinforcements due to their small diameters.
• Examples: Graphite and alumina.
 Fibre Reinforced Composites
Constitutents
• These are composite materials made up of
a) A polymer matrix
b) A filament
c) A bonding agent (which ties fibre filaments to polymers)
• Commonly used fibres are glass or metallic. These fibres are employed either in continuously or
discontinuously as staples or whiskers.

Properties of fibre reinforced composites

• The fibre reinforced composites possess,
1) High tensile strength
2) High specific gravity
3) High elastic modulus
4) They are stiff.
5) They possess lower overall density.
Factors governing properties of fibre-reinforced composites are:
1) Nature of fibres and matrix.

2) Properties pf fibres and matrix.

3) Relative volume fraction of fibre and matrix.

4) Orientation and distribution of fibre in matrix phase.

5) Length to diameter ratio of fibre.

6) Strength of interfacial bond between fibre phase and matrix.

• Few important types of fibre reinforced composites, are given in table below :

Composite Fibre phase Matrix phase Properties Application Limitation

1. Glass fibre Glass fibres Ploymers such 1. Lower density 1. Automobile 1. They can be
reinforced (long as well as as nylons, 2. Higher tensile parts used in low
polymer short) polyster etc. strength 2. Pipes temperature
composite 3. Higher impact 3. Transportatio service
resistance n industries conditions;
4. High 4. Industrial because
resistance to flooring polymers
corrosion and 5. Storage matrixes get
chemicals tanks. deteriorated
at higher
temperatures.
2. The stiffness
is
comparatively
low, hence
cannot be
employed as
structural
companents.
2. Carbon fibre Glass fibre Polymers such 1. Higher 1. Used to High cost,
reinforced (long as well as as nylons, density make hence used
polymer small) Polyester etc. 2. Excellent structural generally for
composite resistance components specific
to corrosion e.g. body or purposes only.
3. Dimensional wings of
stability aircraft
even at high helicopter.
temperature 2. Sports
materials or
fishing rods
3. Aramid fibre- (a) Short aramid Polymeric 1. High surface In automobile Price is high, due
reinforced fibres or material area. brakes and to high cost of
polymer discontinuous 2. High aspect clutches. raw materials
composite ratio
3. Toughness to Note : These are
strength about 4 times
4. Heat stability more in
5. High performance
resistance to than that
wear. containing
asbestos.

Hence are best

susbstitutes in
place of
asbestos
containing
material which is
banned due to its
ill effect on
health.
(b) Long Polymeric 1. Ductile like 1. In Practically on
aramid fibre material metals commercial limitations
continuous 2. It can aircrafts except cost.
sustain 2. Helicopter Note : In latest
stresses. parts like commercial
rotor blades, aircrafts (like
motor Boeing-747
housing and Airbus
3. Business 320), about 3-
aircrafts as 5% composite
structural containing
material aramid or its
hybrid fibres
4. Protective with carbon are
apparel employed.
(thermal or
ballistics)
4. Alumina and (a) Al2O3 or Aluminium 1. Low density To make
/ or carbon Carbon fibres Alloy 2. Resistant to engine
fibre-reinforced thermal components in
metal distortion automobile
composite 3. Resistant to industry
wear
4. Creep
resistant

(b) AL2O3 or W Ni and cobalt 1. Excellent To make

( tubgsten) based alloy strength components of
2. Resistant to turbine engine
creep and
rupture at
high
temperature
.
Structural Composites or Layered Composites
A structural consists of both homogeneous and composite materials. Their properties depend
upon, the characteristic properties of the constituent materials as well as the geometric design.

Structural composites are of two types such as;

(a) Laminar composite : e.g. plywood
(b) Sandwich panel : e.g. honeycomb core

Laminar Composites
• It consists of panels or sheets which are two dimensional. These panels possess preferred directions
to achive high strength.
e.g. plywood in which wood and continuous aligned fibre reinforced plastics are in preferred
directions.
• Such successively oriented layers are stacked one above other with preferred directions and then are
cemented. Such an arrangement or orientation ensures varying high strength with each successive
layer.
• Plywood is a laminated composite containing thin layers of wood where layers are alternatively glued
together. This type of layering brings grain of each layer at right angles of ites neighboring layer.
• use of fabric material such as cotton, paper or woven glass fibre dispersed in suitable plastic matrix is
also in practice to make laminar composites.

Properties
• Properties of these composites depend upon :
(a) The properties of its constituents
(b) The geometrical design

• Generally such composites are :

(1) Strong in both directions of reinforcement
(2) Low shear strength
Applications

These Composites are used in many familiar application, such as:

(1) Aerospace
(2) False cellings for diffused lighting etc.
(3) Furniture making.
(4)Automotive and sporting goods
.
Sandwich Panels

This is another special class of layered composite, which is a modular building material designed to
cover buildings and structures.
• These are fabricated by attaching two strong outer sheets called faces to a layer of less dense
material called core. All the above three layers are joined by using adhesive.
• The outer sheets or faces bear most of the in-plane loading and transverse bending stresses. Outer
structures ensure form, weather resistance, and rigidity.
• The core material resists any deformations perpendicular to the face plane and provides shear
rigidity up to a certain extent. Core material has thermal and acoustic insulation properties. If the
thickness of the core material is increased, stiffness also increases considerably.
• Typical skin material or faces include glass or carbon fiber-reinforced plastics, plywood, titanium,
steel, and aluminum alloys.
• Commonly used core materials include synthetic rubbers, balsa wood, and foamed polymers.
• Honeycomb structure is the most popular core material. It is made up of thin foils forming
interlocked hexagonal cells with their axes oriented at right angles to the direction of face sheets as
shown in the diagram.
Applications: Sandwich panels are used in a wide variety of applications such as:
1.Thermal-humidity insulation and waterproofing
2.Floors and walls of buildings
3.Wings of aircraft, boat hulls, ship structure parts
4.Industrial facilities, commercial buildings, cold storage, and residential buildings
• Common or General Applications of Composites:
1.Aerospace
2.Automotive and road transportation
3.Building and civil engineering
4.Defense, security, and ballistics
5.Design, furniture, and home