Composite material

Group No.: 4
60 - Sangeet Khule
61 - Sannidhya Shegaokar
66 - Suraj Chandak
69 - Tushar Amte
Course Co-ordinator : Subject :
Nitin P. Gudadhe Advanced Manufacturing Techniques
TEACHER ASSESSMENT – II
COMPOSITE MATERIALS
Shri Ramdeobaba College of Engineering and Management
COMPOSITE MATERIAL 1

Sr No. Content Page No.
1 INTRODUCTION 3
2 HISTORY OF COMPOSITE MATERIALS 4
3 COMPONENTS 5
4 NEED OF COMPOSITE MATERIALS 6
5 FABRICATION METHODS 7
6 PROPERTIES 9
7 CLASSIFICATION OF COMPOSITES 12
8 NATURAL FIBRES 13
9 APPLICATIONS 21
10 ARTIFICIALLY MADE COMPOSITES 22
11 PARTICLE REINFORCED COMPOSITES 23
12 FIBER REINFORCED COMPOSITES 32
13 STRUCTURAL COMPOSITES 43
14 REFERENCES 54

 A composite can define as “Two inherently different materials that when
combine together produce a material with properties that exceed the
constituent materials”.
 In other words Composite material can be define as a combination of a
matrix and a reinforcement, which when combined gives properties superior
to the properties of the individual components.
INTRODUCTION

 1100’s : Mongols used basic composites of cattle
tendons, horns, bamboo, silk and pine to build their
archery bows.
 1870-1890 : The first synthetic resins were developed
 1930’s : A process for drawing glass into thin strands, or
fibers, and began weaving them into a textile fabric.
 1966 : Kevlar was developed
 2000’s : carbon nanotubes to improve the mechanical,
thermal and electrical properties of the bulk product.
 2010’s : 3-D printing train by printing items with
reinforced fibers.
HISTORY OF COMPOSITE MATERIALS

 Nearly all composite materials consist of two phases :
• Primary phase (matrix) –
forms the matrix within which the secondary
phase is imbedded
• Secondary phase (reinforcement) –
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
COMPONENTS

 Composites unite many of the best qualities that traditional materials have
to offer.
 Composites are improving the design process and end products across
industries, from aerospace to renewable energy.
 Not all the design properties can be achieved by near metal alloys, ceramic
and polymers, composites open up new design opportunities for engineers.
 REASONS
• Composites have a high strength-to-weight ratio.
• Composites are durable.
• Composites open up new design options.
• Composites are now easier to produce.
NEED OF COMPOSITE MATERIALS

 Molding Operations : Using molding operations large
number of composite product are manufactured.
 Different molding methods are:
• Hand lay-up
• Spray up
• Vacuumed-bag molding
• Pressure-bag molding
• Thermal expansion molding
• Autoclave molding
• Centrifugal Casting
• Continuous pultrusion and pulforming.
FABRICATION METHODS

 Other types of fabrication include press
moulding, transfer moulding, pultrusion
moulding, filament winding, casting,
centrifugal casting, continuous casting and slip
forming.
 There are also forming capabilities including
CNC filament winding, vacuum infusion, wet
lay-up, compression moulding, and
thermoplastic moulding.
FABRICATION METHODS

 Composite materials possess a unique combination of
properties such as
• High strength to weight ratio, i.e. lightness in weight.
• Better toughness, fatigue and stiffness.
• Functional superiority, i.e. better corrosion.
• weathering and fire resistance, electrical insulation
and anti-friction properties.
• Ease of fabrication or versatility of fabrication
methods.
• Better durability and low maintenance cost.
PROPERTIES

Properties of composite varies according to the
 Percentage
 Size
 Shape
 Distribution
 Orientation
CHANGES IN PROPERTIES

SECTOR WISE COMPOSITE MATERIALS

CLASSIFICATION OF COMPOSITES

 A composite material consisting of a polymer matrix embedded with high-
strength natural fibers.
 All fibers which come from natural sources.
 The vegetable world is full of examples where cells or groups of cells are
'designed' for strength and stiffness.
 A sparing use of resources has resulted in optimization of the cell functions.
 Cellulose is a natural polymer with high strength and stiffness per weight,
and it is the building material of long fibrous cells. These cells can be found in
the stem, the leaves or the seeds of plants.
NATURAL FIBRES 13
NATURAL FIBRES

NATURAL FIBRES 14
CLASSIFICATION OF NATURAL FIBRES

 Low specific weight results in higher specific strength and stiffness than
glass.
 It is a renewable source, the production requires little energy, and CO2 is
used while oxygen is given back to the environment.
 Reduced wear of tooling, healthier working condition, and no skin
irritation.
 Producible with low investment at low cost, which makes the material an
interesting product for low wage countries.
 Good electrical resistance.
 Good thermal and acoustic insulating properties.
 Biodegradable.
NATURAL FIBRES 15
ADVANTAGES

 Lower strength, especially impact strength.
 Variable quality, influenced by weather.
 Poor moisture resistance, which causes swelling of fibers.
 Restricted maximum processing temperature.
 Lower durability.
 Poor fire resistance.
 Hydrophilic - low wetting with hydrophobic polymers.
NATURAL FIBRES 16
DISADVANTAGES

 In principle, the production techniques for natural fibre composites can be
similar to those for glass fibres.
 RTM, vacuum injection
• Resin transfer moulding or vacuum injection are clean, closed mould
techniques. Dry fibres are put in the mould, then the mould is closed by
another mould or by just a bagging film and resin is injected. Either with
over-pressure on the injection side or vacuum at the other side the fibres
are impregnated. Tailored lay-ups and high fibre volume contents are
possible. Preforming is pressing the mats with a small amount of binder (like
H2O) into a more compact shape.
• Dense mats of flax can be difficult to impregnate. Better resin flow can then
be obtained by using the thicker leaf fibres like sisal.
NATURAL FIBRES 17
MANUFACTURING PROCESSING
TECHNIQUES

NATURAL FIBRES 18
RESIN TRANSFER MOULDING

 Composite laminates in glass polyester are produced in a continuous way up
to a width of 3 m and with infinite length.
 Bonded on two sides of a foam block they build stiff sandwich panels that
are used a lot in trucks, trailers and building construction. They provide
thermal insulation and can fulfill a primary structural function.
 Small scale prototyping has proved that substitution of glass by natural
fibres is feasible. A bit less insulating, but still very well suitable for wall and
roof construction are sandwiches made of natural fibre composite skins and
bamboo pillars as the sandwich core.
NATURAL FIBRES 19
SANDWICH TECHNOLOGY

NATURAL FIBRES 20
SANDWICH PANEL PRODUCTION

 Storage devices: post-boxes, grain storage silos, bio-gas
containers, etc.
 Furniture: chair, table, shower, bath units, etc.
 Electric devices: electrical appliances, pipes, etc.
 Everyday applications: lampshades, suitcases, helmets,
etc.
 Transportation: automobile and railway coach interior,
boat, etc.
 Luggage.
 Aerospace.
NATURAL FIBRES 21
APPLICATIONS

 PARTICLE REINFORCED COMPOSITES
 FIBER REINFORCED COMPOSITES
 STRUCTURAL COMPOSITES
ARTIFICIALLY MADE COMPOSITES

PARTICLE REINFORCED COMPOSITES 23
PARTICLE REINFORCED
COMPOSITES

 Particle reinforcing in composites is a less
effective means of strengthening than fibre
reinforcement.
 Particulate reinforced composites achieve gains in
stiffness primarily, but also can achieve increases
in strength and toughness.
 Particulate reinforced composites find
applications where high levels of wear resistance
are required such as road surfaces.
 The hardness of cement is increased significantly
by adding gravel as a reinforcing filler.
PARTICLE REINFORCED COMPOSITES

 There are essentially two types of particle reinforced
composites :
• Large particle reinforced.
• Small particle reinforced composites.
 It is not strictly the physical dimensions of the particles by
which the materials are classified, rather it is the mechanism of
reinforcement.
CLASSIFICATION OF PRC

 In a Large particle reinforcement involves larger particles and a distribution
of the load between phases.
 The particle-matrix interaction is treated in macroscopic level. Particle
 size=1-50µm.
 Concentration=15-40% by volume.
 Particulate phase is harder and stiffer than matrix.
 Matrix phase transfers applied stress to particle which bears most of the
applied load.
 Reinforcement depends on volume fraction and strength of bonding.
 Particles of different dimensions should be equiaxed.
LARGE REINFORCED COMPOSITES

 In a small particle reinforced material the mechanism is on a molecular level
and the particles may be dispersed into or precipitated from the matrix.
 Uniformly dispersed fine, hard and inert particle is used for reinforcement
 Particle size < 0.1um
 Volume fraction is between 15-40%.
 More stronger than pure metal.
 Can be metallic, non-metallic, intermetallic.
 Dispersoids are carbides, oxides, borides.
 Shape can be round, disc, needle(max strength).
DISPERSION STRENGTHENED
COMPOSITES

 Less extensive than fibrous reinforcements.
 Isotropic properties.
 Improves the machinability of the material.
 Compatible with most metalworking process and often
fabricated to near net shape fabricated to near net shape.
 Support higher tensile, compressive and shear stresses.
 Ability to tailor the mechanical properties through selection
of reinforcement type and volume fraction along with the
metal alloy.
ADVANTAGES

 The process where the particulate reinforcement form being formed
 Examples of the particulate processing :
• Powder Processing
• Granulation
• Pelletizing
• Particle size reduction through hammer mill
• Particle size reduction through roller mills
• Steam Drying of Fibrous Particulates
TECHNIQUES

 Concrete is a simple, everyday example of a PRC.
 The most common matrix is a Portland cement paste.
 This material is reinforced with aggregate (the dispersed phase) such as
pebbles or chippings (1-2 cm) and sand (1-2 mm).
 The initial setting reactions of the concrete are exothermic and, when only
cement and water are used, this leads to problems with heat dissipation and
cracking.
 Concrete often contains an additional phase in the form of steel wire, rods
or cable to give even greater strength.
APPLICATIONS

 Refractory carbides are hard, wear-resistant ceramic materials such as
titanium and tungsten carbides (TiC and WC).
 They can be incorporated into a matrix of metal, often cobalt or nickel, to
make machine tool cutting tips.
 The carbide provides the wear resistant cutting edge, but by itself would
shatter on impact with the metal being shaped.
 The metal matrix adds resilience and is easier to manufacture.
APPLICATIONS

FIBER REINFORCED COMPOSITES 32
FIBER REINFORCED COMPOSITES

 FRC is high-performance fiber composite achieved & made possible by
cross-linking cellulosic fiber molecules with resins
 A fiber-reinforced composite (FRC) is a composite building material that
consists of three components:
• the fibers as the discontinuous or dispersed phase,
• the matrix as the continuous phase, and
• the fine interphase region, also known as the interface.
 Fiber are characterized by their length to diameter ratio.
 Fiber possess:
• High Strength
• Stiffness
• Greater Elastic Modulus
• Low Density

Fiber Reinforced Composites are made up of :
 Metals, Ceramics, Glasses, or Polymers that have been turned into graphite
and known as Carbon Fibers.
 Fibers increase the modulus of matrix material

CLASSIFICATION OF FRC BASED ON
ORIENTATION OF FIBER

EXAMPLES

 Metal Matrix Composites (MMCs)
• MMCs contain a metal element or alloy as the matrix phase, e.g., aluminum,
magnesium, lead, aluminum-lithium, titanium, copper, and their alloys.
MMCs are usually in the form of particulate composites, which have
aluminum oxide, zirconium oxide, thorium oxide, graphite, titanium carbide,
silicon carbide, boron, tungsten, and molybdenum as example
reinforcements
 Ceramic Matrix Composites (CMCs)
• CMCs have matrix materials such as Al2O3, Si3N4, SiC, ZrO2, TiO2, WC,
Cr2O3, etc., which have melting points of over 1600°C. Reinforcements used
are in the form of monofilaments, fibers, whiskers, particles, and recently
nanoparticles such as CNTs.
CLASSIFIED INTO FOUR GROUPS
ACCORDING TO THEIR MATRICES

 Polymer Matrix Composites (PMCs) or polymeric composites
A composite material composed of a variety of short or continuous fibers
bound together by an organic polymer matrix.
 Carbon/carbon composites (C/C)
Carbon-carbon composites use carbon fibers in a carbon matrix. These
composites are used in very high temperature environments of up to 3315 C,
and are 20 times stronger and 30% lighter than graphite fibers.

 A higher performance for a given weight leads to fuel savings.
 Excellent strength-to-weight and stiffness-to-weight ratios can be achieved
by composite materials.
 Laminate patterns and ply buildup in a part can be tailored to give the
required mechanical properties in various directions.
 Production cost is reduced. Composites may be made by a wide range of
processes.
 Composites offer excellent resistance to corrosion, chemical attack, and
outdoor weathering.
ADVANTAGES

 Composites are more brittle than wrought metals and thus are more easily
damaged.
 Hot curing is necessary in many cases, requiring special equipment.
 Repair at the original cure temperature required tooling and pressure.
DISADVANTAGES

 ELECTRO-SPINNING PROCESS
An electrostatic fiber fabrication technique called
electro-spinning uses electrical forces to generate
continuous fibers of two nanometers to several
micrometer
 FILAMENT WINDING
Filament winding is useful to create axisymmetric, as
well as some non-axisymmetric, composite parts, such
as pipe bends
TECHNIQUES

 used for railings, fences, park benches, molding and trim, window
and door frames, and indoor furniture.
 use in a variety of clinical applications.
 (FRCS) would be naturally considered a strong choice for
automotive body construction due to the high strength-to weight
ratio of such materials and the unique scope for adjusting material
properties.
 Among all the FRC, the fiber-reinforced polymers (FRP) offer the
best combination of cost and performances, and often exhibit
comparable or even better properties than the traditional metallic
materials.
 Sports Equipment.
APPLICATIONS

STRUCTURAL COMPOSITES 43
STRUCTURAL COMPOSITES

 Structural composites are engineered products made from plastic, wood,
glass, or carbon fiber materials.
 The formed or extruded products have applications as outdoor deck floors,
railings, fences, landscape timbers, cladding, siding, moulding, trim, and
window or door frames.
 These low maintenance products are resistant to cracking and can be
smooth or have a simulated wood grain.
 Available in a variety of colors and sizes, structural composites are shaped
using typical woodworking tools.
STRUCTURAL COMPOSITES

 Structural composite materials can be classified as follows:
• Sandwich structures
• Laminates
CLASSIFICATION OF SC

 Sandwich structures : composed by a core and layers. They allow to
improve the mechanical properties but without an excessive increase of
weight. They also improve thermal and acoustic insulation.
 Laminates : A composite laminate is an assembly of layers of fibrous
composite materials which can be joined to provide required engineering
properties, including in-plane stiffness, bending stiffness, strength, and
coefficient of thermal expansion. The individual layers consist of high-
modulus, high-strength fibers in a polymeric, metallic, or ceramic matrix
material. Typical fibers used include cellulose, graphite, glass, boron, and
silicon carbide, and some matrix materials are epoxies, polyimides,
aluminum, titanium, and alumina.

 A higher performance for a given weight leads to fuel savings. Excellent
strength-to weight and stiffness-to-weight ratios can be achieved by
composite materials. This is usually expressed as strength divided by density
and stiffness (modulus) divided by density. These are so-called "specific"
strength and "specific" modulus characteristics.
 Laminate patterns and ply buildup in a part can be tailored to give the
required mechanical properties in various directions.
 Production cost is reduced. Composites may be made by a wide range of
processes.
ADVANTAGES

 Composites are more brittle than wrought metals and thus are more easily
damaged. Cast metals also tend to be brittle.
 If rivets have been used and must be removed, this presents problems of
removal without causing further damage.
 Repair at the original cure temperature requires tooling and pressure.
DISADVANTAGES

 CONTACT MOULDING
This is the oldest and most primitive manufacturing process but also the most
widely used around the world. In contact moulding resin is manually applied to
a dry reinforcement placed onto a tool surface and can be compared to gluing
wall paper with a brush. The tool and fabric are then enclosed by a vacuum bag
and the air under the bag removed in order to cure the laminate under
atmospheric pressure.
TECHNIQUES

 Resin transfer moulding (RTM) is a closed-mould process for
manufacturing high performance composite components in
medium volumes (1,000s to 10,000s of parts). Moulds typically
consist of matched metal tools into which a dry fibre preform
is inserted
1. The mould is then closed.
2. and clamped shut before pumping resin into the tool cavity
to thoroughly wet-out the fibres.
3. The tool will often be heated to assist with the curing of the
resin.
4. Once the resin is cured, the tool can be opened and the part
removed.
TECHNIQUES

 Sustainability of engineered wood products in construction : All SCL
products are used as beams and can substitute for sawn timber in
application, i.e., they can be used as joists, rafters and similar structural
elements. They have engineering design properties with a very low
statistical coefficient of variation of between 10 and 15% which implies that,
on average, the wood fibre is being used more efficiently.
APPLICATIONS

 Sustainability of engineered wood products : Structural composite lumber
(SCL) is of US origin as the use of the term lumber suggests. The first
manufacturing method relies on rotary peeling of logs (laminated veneer
lumber or LVL and parallel strand lumber or PSL), and the second (laminated
strand lumber LSL and oriented strand lumber OSL) relies on a stranding
process.
APPLICATIONS

 PAPERS
 Review of Composite Materials and Applications, M.K.S.Sai, (2016)
 A review of natural fifibers and processing operations for the production of
binderless boards, (2016)
 A REVIEW ON NATURAL FIBERS D. Chandramohan1 & Marimuthu, (2011)
 Adikwu, M.U., 2012. Introduction. In: Biopolymers in Drug Delivery: Recent
Advances and Challenges. Bentham Science Publishers, pp. 1–6.
 Ahmed, E.M., 2015. Hydrogel: preparation, characterization and applications.
a review. J. Adv. Res. 6, 105–121.
 Tanzi, M. C., Farè, S., & Candiani, G. (2019). Organization, Structure, and
Properties of Materials.
REFERENCES

 Fiber reinforced composites :Seçkin Erden, Kingsley Ho, in Fiber Technology
for Fiber-Reinforced Composites, 2017
 A. Deb, in Materials, Design and Manufacturing for Lightweight Vehicles,
2010 , P.K. VALLITTU, in Dental Biomaterials, 2008
 Fiber-Reinforced Polymer Composites: Manufacturing, Properties, and
Applications, 2019

 WEBSITES
 https://discovercomposites.com/what-are-composites/history-of-composites/
 https://3dfortify.com/composites-replace-traditional-materials/
 http://compositeslab.com/composites-manufacturing-processes/
 http://www.fao.org/3/Y1873E/y1873e0a.htm
 https://clubtechnical.com/fiber-reinforced-plastic
 http://buildipedia.com/knowledgebase/division-06-wood-plastics-and-
composites/06-70-00-structural-composites/06-70-00-structural-
composites#:~:text=Structural%20composites%20are%20engineered%20produ
cts,and%20window%20or%20door%20frames.
 https://www.aimplas.net/blog/types-of-composite-materials/
 https://www.sciencedirect.com/topics/materials-science/structural-
composite-material

THANK YOU

Composite material

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