Composite Materials - My First PPT

7/23/2019 Composite Materials - My First PPT

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FAILURE OFCOMPOSITESASHORT SEMINAR

BY

kiRUBHAKARan


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What is a composite material ?

A composite is comprised of two or more different materials(ordifferet phases of the same material! "ith the properties of thecomposite #ei$ #etter tha that of the compoet materials %

E&amples of at'ral composites icl'de humanteethad mud bricks

reiforced "ith straw% E&amples of adaced composite materialsicl'de sports equipment (e.G., Carbon fibre-reinforced o!f c!"b#$and thermal protectio for space re-entry vehicles )

(e.G., Carbon carbon composites!%

Composite materials are ormall* comprised of t"o compoets% The

mai part of the composite is +o" as the matrix. Iside the matri&are inforcing phase.


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Where it is 'sed ?

Composites is the fastest growing

,materials, mar+et se$met%

Sporti$ $oods) Aircraft) a'tomo#ile)ship#'ildi$) are -'st a fe" e&amples% Teis

rac+ets) $olf cl'#s. #'m#ers) door paels)

dash#oard) ee e$ie compoets ofmoder a'tomo#iles. loo+ closel* at a

/oei$ 000) etc%


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Which limits its 'se ?

Limiti$ factors are

1%the cost and reluctance of trasformi$

coetioal metal prod'cts)(#! lac+ of super-fast manufacturing

process i the a'to id'str*)

(c! cost%


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Three mai classificatios2Polymer Matrix Composites (PMC3s! 4Also +o" as FRP 5 Fibre

Reinforced Polymers (or Plastics! 4 these materials 'se a pol*mer5#ased resi as the matri&) ad a ariet* of fi#res s'ch as glass)

carbonad aramidas the reiforcemet%

2Metal Matrix Composites (MMC3s! 5 Icreasi$l* fo'd i the

automotiveid'str*) these materials 'se a metal s'ch asaluminiumas the matri&) ad reiforce it "ith fi#res s'ch as silicon

carbide%

2Ceramic Matrix Composites (CMC3s! 5 Used i very high

temperature eiromets) these materials 'se a ceramicas the

matri& ad reiforce it "ith short fibres) or "his+ers s'ch as those

made from silicon carbide ad boron nitride


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Reaso For 6isaster

Appro&imatel* 78 secods after la'ch) a s'itcase5si9e piece of

thermal is'latio foam #ro+e off the E&teral Ta+ (ET!) stri+i$

Col'm#ia:s left "i$ Reinforced Carbon-Carbon (RCC! paels%

As demostrated #* $ro'd e&perimets cod'cted #* the

Columbia !ccident "nvestigation #oard) this li+el* created a

;5to51


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This ima$e is a ie" of the 'derside of Col'm#ia d'ri$ its etr* from missio

STS51


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!PP$"C!%"&'(

&F

C&MP&("%) M!%)R"!$(


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CRDOEBIC FUEL TAB

Re'sa#le oe5piece li'id

h*dro$e f'el ta+s for la'ch

ehicles ('p to 7%= m diameter

ad 8>%> m lo$!%

Composite f'el ta+s are1


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*nmanned combat air vehicle

+*C!, /oei$ 5>= militar* 'maedcom#at air ehicle (UCAJ! "ith

a plaed com#at radi's of

appro&imatel* 8)


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Power poles and cross arms

Composite po"er poles ad

cross arms to #e mar+eted #*

lar$est Borth America ma+er

of "oode 'tilit* poles%

Poles are prod'ced fromp'ltr'ded fi#re$lass5reiforced

pol*mer composites%

Serice life of 7< *ears ma+es

them ideal for istallatio i

remote areas%

Bo5cod'ctie) rot5resistat)

li$ht"ei$ht cross arms

prod'ced from p'ltr'ded

fi#re$lass5reiforced pol*ester


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.igh performance cars

The 'se of car#o

fi#repol*mer composites ca

res'lt i "ei$ht sai$s of

0=G7> +$

compared to the e'ialet

steel ersio


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Fibreglass tanks and tubes

The direct cost of metallic

corrosio i the U%S% is

estimated to #e USN 80; #illio

each *ear%

This is e'ialet to @H of

$ross domestic prod'ct (6P!%

E&amples icl'de hi$h"a*s)

#rid$es) pipelies) "ater adse"a$e s*stems) ships ad

aircraft) id'strial plats) ad

militar* istallatios


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Civilian aircraft

The Air#'s A@7< c'rretl*

'der ma'fact're "ill

ma+e

'se of si$ificat amo'tsof

composite materials for

the

f'sela$e) tail "i$)

aileros)

ad press're #'l+head%


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SPORTS EIUPMEBT

/ ood fle&i#ilit*

0 E&cellet mechaical

stre$th

1 Lo" specific $rait*2 ood adhesie to

ario's fi#er

3 i$h thermal resistace4 i$h impact stre$th

5 Lo$ pot life


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6ind turbine blades

The 'se of compositematerials

i "id t'r#ie #lades has

res'lted i lar$e adaces i

#lade si9e ad res'lti$ po"er

o'tp't%

Wid t'r#ie #lades ted to

'se mail* $lass fi#re

composites "ith hi$hl*stressed re$ios #ei$

reiforced "ith car#o fi#re

composites%


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.igh temperature composites

o"eer) there are ma*space ad aerospace

applicatios that

re'ire hi$h stre$th(8


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.igh temperature composites


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!RM7 ,)."C$)TPI Composites 'eiled the U%S% Arm*:s first .umvee-like vehicle

made of composite material) "hich proides a "ei$ht sai$s that allo"s

for the carria$e of additioal armor ad other life5sai$ or importat

e'ipmet% (Photo /'siess Wire!


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EBIBEERIB WOO6

)ngineered wood icl'des a "ide ariet* ofdifferet prod'cts s'ch as plywood) orientedstrand board) wood plastic composite (rec*cled

"ood fi#er i pol*eth*lee matri&!) Pykrete(sa"d'sti ice matri&!) Plastic-impregnated or laminatedpaper or te&tiles) !rborite) Formica (plastic! adMicarta%

Other e$ieered lamiate composites) s'ch asMallite) 'se a cetral core of ed $rai #alsa "ood)#oded to s'rface s+is of li$ht allo* or RP% These$eerate low-weight) high rigidity materials%


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o" composites fails ?

The fail're of composites has #ee iesti$ated e&tesiel* from themicromechanicalad macromechanicalpoits of ie"% O themicromechaical scale) fail're mechaisms ad processes ar* "idel*"ith type of loading ad are itimatel* related to the properties of thecostit'et phases) i% e%) matrix)reinforcement) ad interface-interphase% Fail're predictios #ased o micromechaics) ee "he the*are acc'rate "ith re$ard to fail're iitiatio at critical poits) are ol*appro&imate "ith re$ard to global failure of a lamina ad fail'repro$ressio to 'ltimate fail're of a m'lti5directioal lamiate% For thesereasos a macromechaical approach to fail're aal*sis is preferred%


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/est e&ample(hock) impact) or repeated cyclic stresses ca ca'se the lamiate to

separate at the iterface #et"ee t"o la*ers) a coditio +o" as

delamiatio% Idiid'al fi#ers ca separate from the matri& e%$% fiber pull-out

Some composites are brittlead hae little reserve strength #e*od the iitial

oset of fail're "hile others ma* hae large deformations ad hae resere

eer$* absorbing capacity past the oset of dama$e% The ariatios i fi#ersad matrices that are aaila#le ad the mi&t'res that ca #e made "ith #leds

leae a er* #road ra$e of properties that ca #e desi$ed ito a composite

str'ct're% The #est +o" fail're of a #rittle ceramic matri& composite occ'rred

"he the car#o5car#o composite tile o the leadi$ ed$e of the "i$ of the

(pace (huttle Columbia fract'red "he impacted d'ri$ ta+e5off% It led tocatastrophic #rea+5'p of the ehicle "he it re5etered the earth:s atmosphere

o Fe#r'ar* 1) 8


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%ypes of theories

B'mero's fail're theories hae #ee proposedad are aaila#le to the composite str'ct'raldesi$er

The* are classified ito three $ro'ps)2limit or noninteractive theories(ma&im'm

stress) ma&im'm strai!.

2interactive theories(Tsai5ill) Tsai5W'!. ad2partially interactive or failure mode based

theories(ashi5Rotem) P'c+!%


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Uses of these theories

The validity and applicability of a $ie theor* deped o thecoeiece of applicatio ad a$reemet "ith e&perimetalres'lts% The plethora of theories is accompaied #* a dearth ofsuitable and reliable experimental data) "hich ma+es the

selectio of oe theor* oer aother rather diffic'lt%Cosidera#le effort has #ee deoted recetl* to alleiate thisdiffic'lt*% The pro#lem ca #e diided i t"o parts) oe #ei$ theprediction of failure of a single lamina ad the secod deali$"ith prediction of first-ply-failure and damagepro$ressio

leadi$ to 'ltimate fail're of a m'lti5directioal lamiate%


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Cotrasts i those theories

The latter icl'ded uniaxial(ormal ad

shear! loadi$) off-axisloadi$ ad biaxial

(ormal ad shear! loadi$% It "as fo'd) as

o#sered #efore) that most theories differed

little from each other i the first quadrant

(tesio5tesio!% The #i$$est differeces

amo$ theories occ'rred 'der com#ied

transverse compression and shear


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Testi$

To aid i predicting and preventing fail'res)

composites are tested before and after

costr'ctio% Pre5costr'ctio testi$ 'ses

computer aided engineering tools s'ch as ')i(oftware 'astran F)! +finite element analysis

for pl*5#*5pl* aal*sis of c'red s'rfaces ad

predicti$ wrinkling) crimping ad dimplingof

composites%% Materials ma* #e tested aftercostr'ctio thro'$h seeral nondestructive

methods icl'di$ ultrasonics) thermography)

shearography ad8-ray radiography%


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Composites Aal*sis Composite

FEM2The finite element method+F)M(sometimes referred to asfinite element analysis! is a'merical techi'e for fidi$appro&imate sol'tios of partial

differetial e'atios (P6E! as"ell as of ite$ral e'atios% Thesol'tio approach is #ased eithero elimiati$ the differetiale'atio completel* (stead* statepro#lems!) or rederi$ the P6E

ito a appro&imati$ s*stem ofordiar* differetial e'atios)"hich are the 'mericall*ite$rated 'si$ stadardtechi'es s'ch as E'ler:smethod) R'$e5'tta) etc%


31/45

')i (oftware) Ic% has Fiite Elemet Aal*sis (FEA! composites aal*sis

soft"are tools that allo" composite prod'ct ad desi$ e$ieers to e&amie the

structural9 dynamic9 and thermal aspects of their desi$s "ith detailed

$raphical is'ali9atio of data ad res'lts%

The isi$ht $aied #* s'ch aal*sis allo"s desi$ers to easil* tr* alterateapproaches) optimi9e their desi$s) improe 'alit*) red'ce desi$ c*cle time)

ad sae time ad moe* o protot*pes ad first articles% BEi Bastra:s al'e

has #ee proe #* e$ieers i a "ide ariet* of id'stries icl'di$ aerospace)

militar*) a'tomotie) maritime) sports) ad cos'mer prod'cts% Form'la 1 race

cars) America:s C'p *achts) To'r de Frace #ic*cles ad etrepree'rialcommercial s acecraft are 'st a fe" e&am les of hi hl adaced ro ects that

Composites

!nalysis :Composite F)M


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Possible modes of failure of sandwich composite

under edgewise loads;


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Shear Ad Traserse Fail're


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raph5Stress s Strai


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Cosider loadi$ a composite parallel to the fi#res% Sice the* are #oded to$ether) #oth fi#re admatri& "ill stretch #* the same amo't i this directio) i%e% the* "ill hae equal strains9 e(Fi$% 1!%

This meas that) sice the fi#res are stiffer (hae a hi$her7oung modulus9 E!) the* "ill #e carr*i$

a lar$er stress% This ill'strates the cocept of load transfer) orload partitioning #et"ee matri&

ad fi#re) "hich is desira#le sice the fi#res are #etter s'ited to #ear hi$h stresses% /* p'tti$ the

s'm of the cotri#'tios from each phase e'al to the oerall load) the Do'$ mod'l's of the

composite is fo'd (dia$ram!% It ca #e see that a =Rule of Mixtures=applies% This is sometimes

termed the =equal strain=or =,oigt=case% Pa$e 8 i the sectio coers deriatio of the e'atio

for the a&ial stiffess of a composite ad pa$e @ allo"s the effects o composite stiffess of the

fi#rematri& stiffess ratio ad the fi#re ol'me fractio to #e e&plored #* ip'tti$ selected al'es%


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2Short fi#res ca offeradata$es of ecoom* adease of processi$% Whethe fi#res are ot lo$) the

e'al strai coditio olo$er holds 'der a&ialloadi$) sice the stress ithe fi#res teds to fall offto"ards their eds (see Fi$%

@!% This meas that theaera$e stress i the matri&m'st #e hi$her tha for thelo$ fi#re case%


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6elamiatio

.igh stiffness ad strength's'all* re'ire a hi$h proportio

of fi#res i the composite% This is achieed #* ali$i$ a set of

lo$ fi#res i a thi sheet (a laminaor ply!% o"eer) s'ch

material is hi$hl* anisotropic9$eerall* #ei$ "ea+ ad

compliat (hai$ a lo" stiffess! i the traserse directio%

Commol*) hi$h stre$th ad stiffess are re'ired i ario's

directios "ithi a plae% The sol'tio is to stac+ ad "eld

to$ether a 'm#er of sheets) each hai$ the fi#res orieted

i differet directios% S'ch a stac+ is termed a laminate% A

e&ample is sho" i the dia$ram% The cocept of a lamiate)

ad a pictorial ill'stratio of the "a* that the stiffess

#ecomes more isotropicas a si$le pl* is made ito a cross5

pl* lamiate) are preseted i pa$e 1 of this sectio%


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Lamiate theor*


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/ic*cle frames

Failure of Carbon Fibre ReinforcedPolymer +CFRP cycle frames

Carbon Fibre Reinforced

Polymer +CFRP cycle frames


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/ic*cle frames


Carbon Fibre ReinforcedPolymer +CFRP cycle frames


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/ic*cle frame


Carbon Fibre ReinforcedPolymer +CFRP cycle frames

Composite Materials - My First PPT

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