CH 16
CH 16
ISSUES TO ADDRESS...
• What are the classes and types of composites?
• What are the advantages of using composite
materials?
• How do we predict the stiffness and strength of the
various types of composites?
Chapter 16 - 1
Composite
• Combination of two or more _____________
______________
Chapter 16 - 2
Terminology/Classification
• _____________:
-- Multiphase material that is artificially
made.
• Phase types:
-- ________ - is continuous
-- Dispersed - is ____________ and
surrounded by matrix
Chapter 16 - 3
Terminology/Classification
• _________ phase: woven
-- Purposes are to: fibers
- ___________________________
- protect dispersed phase from
environment
-- Types: MMC, CMC, PMC 0.5 mm
cross
metal ________ polymer section
view
• Dispersed phase:
-- Purpose:
MMC: increase _________________. 0.5 mm
CMC: increase KIc Reprinted with permission from
D. Hull and T.W. Clyne, An
PMC: increase E, σy, TS, creep resist. Introduction to Composite Materials,
2nd ed., Cambridge University Press,
-- Types: ________, fiber, structural New York, 1996, Fig. 3.6, p. 47.
Chapter 16 - 4
Classification of Composites
Composites
Aligned Randomly
oriented
Adapted from Fig. 16.2,
Callister & Rethwisch 9e.
Chapter 16 - 5
Classification: Particle-Reinforced (i)
Particle-reinforced Fiber-reinforced Structural
• Examples:
- __________ matrix: particles:
steel ferrite (a) cementite Fig. 11.19, Callister &
Rethwisch 9e.
(ductile) (Fe C) (Copyright 1971 by United
3 States Steel Corporation.)
(brittle)
60 μm
600 μm
(stiff)
0.75 μm Chapter 16 - 6
Classification: Particle-Reinforced (ii)
Particle-reinforced Fiber-reinforced Structural
Concrete – ___________________________________
- Why sand and gravel? Sand fills voids between _______ particles
Reinforced concrete – ____________ with steel rebar or remesh
- increases strength - even if cement matrix is cracked
______________ concrete
- Rebar/remesh placed under tension during setting of concrete
- ___________________________________________________________
- To fracture concrete, applied tensile stress must exceed this
compressive stress
0 20 4 0 6 0 8 0 10 0 vol% tungsten
(Cu) (W)
• Application to other properties:
-- Electrical ________ , σe: Replace E’s in equations with σe’s.
-- ________ conductivity, k: Replace E’s in equations with k’s.
Chapter 16 - 8
Classification: Fiber-Reinforced (i)
Particle-reinforced Fiber-reinforced Structural
• Fibers very strong in tension
– Provide ________________________________
___________________
– Ex: fiber-glass - continuous glass filaments in a
polymer matrix
• Glass fibers
– strength and ____________
• Polymer matrix
– holds fibers in place
– ____________________
– transfers load to fibers
Chapter 16 - 9
Classification: Fiber-Reinforced (ii)
Particle-reinforced Fiber-reinforced Structural
• Fiber Types
– _________ - _______________ - large length to diameter ratios
• ________, silicon nitride, silicon carbide
• high crystal ________ – extremely strong, strongest known
• _________________ and difficult to disperse
– Fibers
• polycrystalline or amorphous
• generally _________________________
• Ex: alumina, aramid, E-glass, boron, UHMWPE
– Wires
• __________ – steel, molybdenum, tungsten
Chapter 16 - 10
Longitudinal
direction
Fiber Alignment
Fig. 16.8, Callister &
Rethwisch 9e.
Transverse
direction
fracture
surface
2 μm
Chapter 16 - 12
Classification: Fiber-Reinforced (iv)
Particle-reinforced Fiber-reinforced Structural
• ________________, random in 2 dimensions
• Example: _____________ C fibers:
-- fabrication process: very stiff
- carbon fibers _________ very strong
in polymer resin matrix, (b)
C matrix:
500 μm
- polymer resin _________ less stiff
at up to 2500°C. view onto plane less strong
-- uses: disk brakes, gas
fibers lie
turbine exhaust flaps,
(a) in plane
missile nose cones.
• Other possibilities:
Adapted from F.L. Matthews and R.L. Rawlings,
-- Discontinuous, random 3D Composite Materials; Engineering and Science,
-- Discontinuous, aligned Reprint ed., CRC Press, Boca Raton, FL, 2000.
(a) Fig. 4.24(a), p. 151; (b) Fig. 4.24(b) p. 151.
(Courtesy I.J. Davies) Reproduced with
permission of CRC Press, Boca Raton, FL.
Chapter 16 - 13
Classification: Fiber-Reinforced (v)
Particle-reinforced Fiber-reinforced Structural
• _____________________ for effective stiffening & strengthening:
fiber ______tensile strength fiber diameter
shear strength of
fiber-matrix ________
• Ex: For ____________, common fiber length > 15 mm needed
• For longer fibers, _______________ from matrix is more efficient
Short, thick fibers: Long, thin fibers:
c = composite
f = fiber
m = matrix
Chapter 16 - 15
Composite Stiffness:
Transverse Loading
• In transverse loading the fibers carry less of the load
c = composite
f = fiber
m = matrix
Chapter 16 - 16
Composite Stiffness
Particle-reinforced Fiber-reinforced Structural
Chapter 16 - 17
Composite Strength
Particle-reinforced Fiber-reinforced Structural
Chapter 16 - 18
Composite Production Methods (i)
__________________
• Continuous fibers pulled through resin tank to impregnate fibers with
_________________________
• Impregnated fibers pass through steel die that preforms to the desired shape
• Preformed stock passes through a curing die that is
– _____________________________________
– _____________________________________
Chapter 16 - 19
Composite Production Methods (ii)
• Filament Winding
– Continuous reinforcing fibers are accurately positioned in a predetermined
pattern to form ________________________________________
– Fibers are fed through a resin bath to impregnate with _________________
– Impregnated fibers are continuously wound (typically automatically) onto a
____________
– After appropriate number of layers added, curing is carried out either in an
oven or at room temperature
– _________________________________________________
Fig. 16.15, Callister & Rethwisch 9e.
[From N. L. Hancox, (Editor), Fibre Composite Hybrid
Materials, The Macmillan Company, New York, 1981.]
Chapter 16 - 20
Classification: Structural
Particle-reinforced Fiber-reinforced Structural
• Laminates -
-- stacked and bonded _____________ sheets
- stacking sequence: e.g., 0º/90º Adapted from
- benefit: _________________________ Fig. 16.16,
Callister &
Rethwisch 8e.
• _____________________
-- ___________________between two facing sheets
- benefits: low density, large bending stiffness
face sheet
adhesive layer
honeycomb
resistance w/SiC
whiskers
10 -10
σ (MPa)
20 30 50 100 200 Chapter 16 - 22
Summary
• Composites types are designated by:
-- the matrix material (CMC, MMC, PMC)
-- the reinforcement (particles, fibers, structural)
• Composite property benefits:
-- MMC: enhanced E, σ, creep performance
-- CMC: enhanced KIc
-- PMC: enhanced E/ρ, σy, TS/ρ
• Particulate-reinforced:
-- Types: large-particle and dispersion-strengthened
-- Properties are isotropic
• Fiber-reinforced:
-- Types: continuous (aligned)
discontinuous (aligned or random)
-- Properties can be isotropic or anisotropic
• Structural:
-- Laminates and sandwich panels
Chapter 16 - 23