Composite Materials Fundamental questions How do composite materials differ from other engineering...
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Composite MaterialsFundamental questions
• How do composite materials differ from other engineering materials?
• What are the constituent materials, and how do their properties compare?
• How do the properties of the composite depend on the type, amount and arrangement of the constituents?
• How are composite products made, and why does manufacture affect quality?
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Fibres have better stiffness and strength compared to bulk materials
• Atomic or molecular alignment(carbon, aramid)
• Removal of flaws and cracks (glass)
• Strain hardening (metals)
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fibre advantages disadvantages
glass high strengthlow cost
low stiffness
aramid high tensile strengthlow density
low compressivestrengthmoisture absorption
boron high stiffnesshigh compressivestrength
high cost
‘HS’ carbon high strengthhigh stiffness
moderately high cost
‘HM’ carbon very high stiffness low strengthhigh cost
ceramic high stiffnesshigh usage ature
low strengthhigh cost
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0 100 200 300 400 500 600
E-glass
S-glass
T300 carbon
IM-7 carbon
GY70 graphite
boron
aramid
SiC (Textron)
Saphikon alumina
Fibre Tensile Modulus (GPa)
0 1000 2000 3000 4000 5000 6000
E-glass
S-glass
T300 carbon
IM-7 carbon
GY70 graphite
boron
aramid
SiC (Textron)
Saphikon alumina
Fibre Tensile Strength (MPa)
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Most reinforcing fibres are brittle (elastic to failure)
Hollaway (ed), Handbook of Polymer Composites for Engineers
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Types of Natural Fibre
• Bast fibres (flax, hemp, jute, kenaf…)- wood core surrounded by stem containing cellulose filaments
• Leaf fibres (sisal, banana, palm)
• Seed fibres (cotton, coconut (coir), kapok)
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Density of natural fibres
0
0.5
1
1.5
2
2.5
3
E-glass
flax hemp jute ramie coir sisal abaca cotton
g/c
m3
TNO Centre for Lightweight Structures
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Tensile strength
0
500
1000
1500
2000
2500
3000
E-glass
flax hemp jute ramie coir sisal abaca cotton
MP
a
Specific tensile strength
0
200
400
600
800
1000
1200
E-glass
flax hemp jute ramie coir sisal abaca cotton
MP
a /
(g/m
3)
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Tensile modulus
0
10
20
30
40
50
60
70
80
90
E-glass
flax hemp jute ramie coir sisal abaca cotton
GP
a
Specific tensile modulus
0
10
20
30
40
50
60
E-glas
sfla
xhe
mpjut
era
mieco
irsis
al
abac
a
cotto
n
GP
a /
(g/m
3)
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High specific properties (low density).
A renewable resource; production requires relatively little energy
Crops are sink for CO2, returning oxygen to atmosphere.
Low investment and low cost production.
Low tooling wear.
Better working conditions, no skin irritation.
Thermal recycling possible.
Good thermal and acoustic insulating properties.
Advantages of Natural Fibres
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Low strength, especially impact strength.
Variable quality (e.g. weather dependent).
Moisture absorption, which causes swelling of the fibres.
Limited maximum processing temperature.
Lower durability (potential for improvement through fibre treatments).
Poor fire resistance.
Price fluctuation (harvest results or agricultural politics).
Irregular fibre lengths (spinning is required to obtain continuous yarns).
Disadvantages of Natural Fibres
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Structures cannot be made from fibres alone - the high properties of fibres are not realisable in practice
A matrix is required to:
• hold reinforcement in correct orientation
• protect fibres from damage
• transfer loads into and between fibres
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COMPOSITES - A FORMAL DEFINITION(Hull, 1981)
1. Consist of two or more physically distinct and mechanically separable parts.
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Polymer matrix composite combinations
Fibre
E-glassS-glasscarbon (graphitearamid (eg Kevlar)boron
Matrix
epoxypolyimidepolyesterthermoplastics (PA, PS, PEEK…)
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Ceramic matrix composite combinations
Fibre
SiCaluminaSiN
Matrix
SiCaluminaglass-ceramicSiN
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Metal matrix composite combinations
Fibre
boronBorsiccarbon (graphite)SiCalumina (Al2O3)
Matrix
aluminiummagnesiumtitaniumcopper
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0 20 40 60 80
GPa
CSM glass/polyester (Vf 25%)
biaxial woven glass/epoxy (Vf 50%)
UD glass/epoxy (Vf 60%)
E-glass fibres
Tensile Modulus
Composite property might be only 10% of the fibre property:
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fibre CSM glass woven glass filament-wound UDglass
wovenaramid
UD aramid UD HS carbon UD HM carbon
resin polyester polyester polyester polyester epoxy epoxy epoxyVf 17% 32% 44% 48% 60% 63% 60%SG 1.46 1.7 1.83 1.3 1.35 1.6 1.6tensile strength(MPa)
110 220 650 390 1380 2280 1260
tensilemodulus (GPa)
8 14 30 24 76 142 200
tensileelongation (%)
1.6 1.7 1.9 1.8 1.5 0.5
compressionstrength (MPa)
150 230 800 86 276 1440 840
shear strength(MPa)
80 90 50 60 71 65
shear modulus(GPa)
3 3.3 4 2.1 7.2 5.5
Some typical polymer composite properties
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Examples of particulate composites
• Concrete - hard particles (gravel) + cement (ceramic/ceramic composite). Properties determined by particle size distribution, quantity and matrix formulation
• Additives and fillers in polymers:carbon black (conductivity, wear/heat resistance)aluminium trihydride (fire retardancy)glass or polymer microspheres (density reduction)chalk (cost reduction)
• Cutting tool materials and abrasives (alumina, SiC, BN bonded by glass or polymer matrix; diamond/metal matrix)
• Electrical contacts (silver/tungsten for conductivity and wear resistance)
• Cast aluminium with SiC particles
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COMPOSITES - A FORMAL DEFINITION(Hull, 1981)
1. Consist of two or more physically distinct and mechanically separable parts.
2. Constituents can be combined in a controlled way to achieve optimum properties.
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Examples of natural composites
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COMPOSITES - A FORMAL DEFINITION(Hull, 1981)
1. Consist of two or more physically distinct and mechanically separable parts.
2. Constituents can be combined in a controlled way to achieve optimum properties.
3. Properties are superior, and possibly unique, compared those of the individual components
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Addition of properties:
GLASS + POLYESTER = GRP
(strength) (chemical resistance) (strength and chemical resistance)
Unique properties:
GLASS + POLYESTER = GRP
(brittle) (brittle) (tough!)
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ADVANCED COMPOSITES vs REINFORCED PLASTICS
• Aerospace, defence, F1…• Highly stressed• Glass, carbon, aramid fibres• Honeycomb cores• Epoxy, bismaleimide…• Prepregs• Vacuum bag/oven/autoclave
• Highly tested and qualified materials
• Marine, building…• Lightly stressed• Glass (random and woven)• Foam cores• Polyester, vinylester…• Wet resins• Hand lay up, room
temperature cure
• Limited range of lower performance materials
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Why are composites used in engineering?
• Weight saving (high specific properties)• Corrosion resistance• Fatigue properties• Manufacturing advantages:
- reduced parts count- novel geometries- low cost tooling
• Design freedoms- continuous property spectrum- anisotropic properties
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Anisotropic properties - fibres can be aligned in load directions to make the
most efficient use of the material
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The ability to vary fibre content and orientation results in a spectrum of available properties
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Why aren’t composites used more in engineering?
• High cost of raw materials• Lack of design standards• Few ‘mass production’ processes available• Properties of laminated composites:
- low through-thickness strength- low interlaminar shear strength
• No ‘off the shelf’ properties - performance depends on quality of manufacture
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There are no ‘off the shelf’ properties with composites. Both the structure and the material are
made at the same time.
Material quality depends on quality of manufacture.
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Poor quality - low fibre content, high void content
Good quality - high fibre content, ‘zero’ void content