Imam Khomeini International University

Faculty of Eng.- Dept. of Materials Engineering

COMPOSITE MATERIALS

Presented by:
Dr. S.M.K. Hosseini
Smk_hosseini@ikiu.ac.ir
hossinim@ioec.com
Classification
Reinforcing Phase
Properties
Other Structures
Metal Matrix Composites
Ceramic Matrix Composites
Polymer Matrix Composites

Composite is a materials system composed of two or more physically distinct “

phases whose combination produces aggregate properties that are different
”from those of its constituents
 1.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
Examples:
Cemented carbides (WC with Co binder)
Plastic molding compounds containing fillers
Rubber mixed with carbon black
Wood (a natural composite as distinguished from a
synthesized composite)
 1. Why Composites are Important
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
 1. Disadvantages and Limitations of
Composite Materials
Properties of many important composites are
anisotropic ‑ the properties differ depending on the
direction in which they are measured – this may be an
advantage or a disadvantage
Many of the polymer‑based composites are subject to
attack by chemicals or solvents, just as the polymers
themselves are susceptible to attack
Composite materials are generally expensive
Manufacturing methods for shaping composite
materials are often slow and costly
 1. One Possible Classification of
Composite Materials
Traditional composites – composite materials that
occur in nature or have been produced by civilizations
for many years
Examples: wood, concrete, asphalt
Synthetic composites - modern material systems
normally associated with the manufacturing industries,
in which the components are first produced separately
and then combined in a controlled way to achieve the
desired structure, properties, and part geometry
Classification .1
 1. Classification
Primary Phase, Matrix

,Secondary Phase
Reinforcement
 2. Functions of the Matrix Material
(Primary Phase)
Protect phases from environment
Transfer Stresses to phases
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
2. Reinforcing Phase (Secondary)
Metal & Ceramic Matrix Composites
 Cermets
 Ceramic (up to 90%) contained in a metallic matrix
 Cemented Carbides (tungsten, titanium, chromium)
 Cutting Tools, Dies, Indenters
 Fibre Reinforced
 Matrix is typically low density (e.g. al., mg., titanium)
 Fibres are typically Al2O3, Boron, Carbon, SiC
 Ceramic Matrix Composites
 Ceramic primary phase and fibres in secondary phase
Polymer Matrix Composites
Fibre reinforced polymers (FRPs)
Polymer matrix reinforced with fibres
Matrix is typically TP (polyester or epoxy) and TS
such as nylons, pvc, polycarbonates and polystyrene
Fibres are typically glass, carbon and Kevlar 49 (up to
50%)
Components in a Composite Material
Nearly all composite materials consist of two phases:
Primary phase - forms the matrix within which the
secondary phase is imbedded
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
 Fibers
Filaments of reinforcing material, usually circular in
cross‑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
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
 Materials for Fibers
Fiber materials in fiber‑reinforced composites:
Glass – most widely used filament
Carbon – high elastic modulus
Boron – very high elastic modulus
Polymers - Kevlar
Ceramics – SiC and Al2O3
Metals - steel
The most important commercial use of fibers is in
polymer composites
 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
 Properties of Composite Materials
In selecting a composite material, an optimum
combination of properties is usually sought, rather than
one particular property
Example: fuselage and wings of an aircraft must be
lightweight and be strong, stiff, and tough
 Several fiber‑reinforced polymers possess this combination of
properties
Example: natural rubber alone is relatively weak
 Adding significant amounts of carbon black to NR increases its
strength dramatically
 Properties are Determined by
Three Factors:
The materials used as component phases in the
composite
The geometric shapes of the constituents and resulting
structure of the composite system
The manner in which the phases interact with one
another
Rule of Mixtures
Variation in elastic modulus and tensile strength as a function of direction of
measurement relative to longitudinal axis of carbon fiber ‑reinforced epoxy
composite
 Fibers Illustrate Importance of
Geometric Shape
Most materials have tensile strengths several times
greater as fibers than in bulk
By imbedding the fibers in a polymer matrix, a
composite material is obtained that avoids the
problems of fibers but utilizes their strengths
The matrix provides the bulk shape to protect the fiber
surfaces and resist buckling
When a load is applied, the low‑strength matrix deforms
and distributes the stress to the high‑strength fibers
 Other Composite Structures
Laminar composite structure – conventional
Sandwich structure
Honeycomb sandwich structure
 Other Laminar Composite Structures
 Automotive tires - consists of multiple layers bonded together
 FRPs - multi‑layered fiber‑reinforced plastic panels for aircraft,
automobile body panels, boat hulls
 Printed circuit boards - layers of reinforced plastic and copper
for electrical conductivity and insulation
 Snow skis - composite structures consisting of layers of metals,
particle board, and phenolic plastic
 Windshield glass - two layers of glass on either side of a sheet of
tough plastic
 Metal Matrix Composites (MMCs)

A metal matrix reinforced by a second phase

Reinforcing phases:
Particles of ceramic (these MMCs are commonly called
cermets)
Fibers of various materials: other metals, ceramics,
carbon, and boron
 Cermets

MMC with ceramic contained in a metallic matrix

The ceramic often dominates the mixture, sometimes
up to 96% by volume
Bonding can be enhanced by slight solubility between
phases at elevated temperatures used in processing
Cermets can be subdivided into
Cemented carbides – most common
Oxide‑based cermets – less common
 Cemented Carbides
 One or more carbide compounds bonded in a metallic matrix
 The term cermet is not used for all of these materials, even
though it is technically correct
 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)
 Cemented Carbide

Photomicrograph (about 1500X) of cemented carbide with 85% WC and 15% Co

Hardness vs. Transverse Rupture Strength
Typical plot of hardness and transverse rupture strength as a function of
cobalt content
 Applications of Cemented Carbides
 Tungsten carbide cermets (Co binder) - cutting tools are most
common; other: wire drawing dies, rock drilling bits and other
mining tools, dies for powder metallurgy, indenters for hardness
testers
 Titanium carbide cermets (Ni binder) - high temperature
applications such as gas‑turbine nozzle vanes, valve seats,
thermocouple protection tubes, torch tips, cutting tools for steels
 Chromium carbides cermets (Ni binder) - gage blocks, valve
liners, spray nozzles, bearing seal rings
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 tensile
strength, susceptibility to thermal cracking
 CMCs represent an attempt to retain the desirable properties of
ceramics while compensating for their weaknesses
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)
FRPs are most closely identified with the term
composite
 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; its use to reinforce plastics
dates from around 1920
 Common FRP Structure
Most widely used form of FRP is a laminar structure,
made by stacking and bonding thin layers of fiber and
polymer until desired thickness is obtained
By varying fiber orientation among layers, a specified
level of anisotropy in properties can be achieved in the
laminate
Applications: parts of thin cross‑section, such as
aircraft wing and fuselage sections, automobile and
truck body panels, and boat hulls
 FRP Properties
 High strength‑to‑weight and modulus‑to‑weight ratios
 Low specific gravity - a typical FRP weighs only about 1/5 as
much as steel; yet, strength and modulus are comparable in fiber
direction
 Good fatigue strength
 Good corrosion resistance, although polymers are soluble in
various chemicals
 Low thermal expansion - for many FRPs, leading to good
dimensional stability
 Significant anisotropy in properties
 FRP Applications
 Aerospace – much of the structural weight of todays airplanes
and helicopters consist of advanced FRPs
 Automotive – somebody panels for cars and truck cabs
 Continued use of low-carbon sheet steel in cars is evidence of its
low cost and ease of processing
 Sports and recreation
 Fiberglass reinforced plastic has been used for boat hulls since the
1940s
 Fishing rods, tennis rackets, golf club shafts, helmets, skis, bows and
arrows.
Aerospace Applications
 Other Polymer Matrix Composites

In addition to FRPs, other PMCs contain particles,

flakes, and short fibers as the secondary phase
Called fillers when used in molding compounds
Two categories:
Reinforcing fillers – used to strengthen or otherwise
improve mechanical properties
 Examples: wood flour in phenolic and amino resins; and carbon
black in rubber
Extenders – used to increase bulk and reduce cost per
unit weight, but little or no effect on mechanical
properties
 Guide to Processing Composite Materials
The two phases are typically produced separately
before being combined into the composite part
Processing techniques to fabricate MMC and CMC
components are similar to those used for powdered
metals and ceramics
Molding processes are commonly used for PMCs with
particles and chopped fibers
Specialized processes have been developed for FRPs