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Muhammad Umair Bukhari

   Engr.umair.bukhari@gmail.com
      www.bzuiam.webs.com
         03136050151
A broad definition of composite is: Two or more chemically distinct
   materials which when combined have improved properties over
   the individual materials. Composites could be natural or synthetic.


  Wood is a good example of a natural composite, combination of cellulose
  fiber and lignin. The cellulose fiber provides strength and the lignin is the
  "glue" that bonds and stabilizes the fiber.

  Bamboo is a very efficient wood composite structure. The components
  are cellulose and lignin, as in all other wood, however bamboo is
  hollow. This results in a very light yet stiff structure. Composite fishing
  poles and golf club shafts copy this natural design.

  The ancient Egyptians manufactured composites! Adobe bricks are a good
  example. The combination of mud and straw forms a composite that is
  stronger than either the mud or the straw by itself.
                                                                                  3
Ken Yossefi
Composites are combinations of two materials in which one of the material is
    called the reinforcing phase, is in the form of fibers, sheets, or particles, and
    is embedded in the other material called the matrix phase.

    Typically, reinforcing materials are strong with low densities while the
    matrix is usually a ductile or tough material. If the composite is designed
    and fabricated correctly, it combines the strength of the reinforcement with
    the toughness of the matrix to achieve a combination of desirable
    properties not available in any single conventional material.

Components of composite materials

     Reinforcement: fibers             Matrix materials           Interface
               Glass                         Polymers             Bonding
               Carbon                        Metals               surface
               Organic                       Ceramics
               Boron
               Ceramic
               Metallic                                                             4
Ken Youssefi                       Mechanical Engineering Dept.
The essence of the concept of composites is that the load is applied
        over a large surface area of the matrix. Matrix then transfers the load
        to the reinforcement, which being stiffer, increases the strength of the
        composite. It is important to note that there are many matrix materials
        and even more fiber types, which can be combined in countless ways
        to produce just the desired properties.

        In the United States, composites manufacturing is a 25 billion dollar
        a year industry. There are about 6000 composites related
        manufacturing plants and materials distributors across the U.S. The
        industry employs more than 235,000 people. An additional 250,000
        people are employed in businesses that support the composites
        industry, including materials suppliers, equipment vendors, and other
        support personnel.

        About 90% of all composites produced are comprised of glass fiber and
        either polyester or vinylester resin. Composites are broadly known as
        reinforced plastics.
                                                                                   5
Ken Youssefi                        Mechanical Engineering Dept.
Composites

Fibers




Matrix materials




                   Mechanical Engineering Dept.   Ken Youssefi   6
Polymer matrix composites (PMC) and fiber reinforced plastics (FRP)
       are referred to as Reinforced Plastics. Common fibers used are
       glass (GFRP), graphite (CFRP), boron, and aramids (Kevlar). These
       fibers have high specific strength (strength-to-weight ratio) and specific
       stiffness (stiffness-to-weight ratio)




     Matrix materials are usually thermoplastics or thermosets; polyester,
     epoxy (80% of reinforced plastics), fluorocarbon, silicon, phenolic.

                                                                                    7
Ken Youssefi                        Mechanical Engineering Dept.
Reinforcing fibers
    Glass – most common and the least expensive, high strength, low stiffness
    and high density. GFRP consists 30-60% glass fibers by volume.

   Graphite (99% carbon) or Carbon (80-95% carbon) – more expensive
   than glass fibers, but lower density and higher stiffness with high strength.
   The composite is called carbon-fiber reinforced plastic (CFRP).

    Boron – boron fibers consist of boron deposited on tungsten fibers, high
    strength and stiffness in tension and compression, resistance to high
    temperature, but they are heavy and expensive.

   Aramids (Kevlar) – highest specific strength, toughest fiber, undergoes
   plastic deformation before fracture, but absorbs moisture, and is expensive.

The average diameter of fibers used is usually less than .0004 inch (.01 mm).
The tensile strength of a glass fiber could be as high as 650 ksi (bulk glass
Su = 5-150 ksi)                                                               8
Ken Youssefi                      Mechanical Engineering Dept.
The mechanical properties of reinforced plastics vary with the kind,
shape, relative volume, and orientation of the reinforcing material, and
the length of the fibers.




 Effect of type, length, % volume, and orientation of fibers in a fiber
 reinforced plastic (nylon)
                         Mechanical Engineering Dept.   Ken Youssefi       9
Phenolic as a matrix with asbestos fibers was the first reinforced plastic
  developed. It was used to build an acid-resistant tank. In 1920s it was
  Formica, commonly used as counter top., in 1940s boats were made of
  fiberglass. More advanced developments started in 1970s.

  Consumer Composites
  Typically, although not always, consumer composites involve products that
  require a cosmetic finish, such as boats, recreational vehicles, bathwear,
  and sporting goods. In many cases, the cosmetic finish is an in-mold
  coating known as gel coat.

  Industrial Composites
  A wide variety of composites products are used in industrial applications, where
  corrosion resistance and performance in adverse environments is critical.
  Generally, premium resins such as isophthalic and vinyl ester formulations are
  required to meet corrosion resistance specifications, and fiberglass is almost
  always used as the reinforcing fiber. Industrial composite products include
  underground storage tanks, scrubbers, piping, fume hoods, water treatment
  components, pressure vessels, and a host of other products.
                                                                                10
Ken Youssefi                      Mechanical Engineering Dept.
Advanced Composites

  This sector of the composites industry is characterized by the use of
  expensive, high-performance resin systems and high strength, high stiffness
  fiber reinforcement. The aerospace industry, including military and
  commercial aircraft of all types, is the major customer for advanced
  composites.
  These materials have also been adopted for use in sporting goods, where
  high-performance equipment such as golf clubs, tennis rackets, fishing poles,
  and archery equipment, benefits from the light weight – high strength offered
  by advanced materials. There are a number of exotic resins and fibers used
  in advanced composites, however, epoxy resin and reinforcement fiber of
  aramid, carbon, or graphite dominates this segment of the market.




                                                                                  11
Ken Youssefi                     Mechanical Engineering Dept.
The metal matrix composites offer higher modulus of elasticity,
       ductility, and resistance to elevated temperature than polymer matrix
       composites. But, they are heavier and more difficult to process.




                                                                               12
Ken Youssefi                       Mechanical Engineering Dept.
Ceramic matrix composites (CMC) are used in applications where
       resistance to high temperature and corrosive environment is desired.
       CMCs are strong and stiff but they lack toughness (ductility)

       Matrix materials are usually silicon carbide, silicon nitride and aluminum
       oxide, and mullite (compound of aluminum, silicon and oxygen). They
       retain their strength up to 3000 oF.

       Fiber materials used commonly are carbon and aluminum oxide.

       Applications are in jet and automobile engines, deep-see mining,
       cutting tools, dies and pressure vessels.




                                                                                    13
Ken Youssefi                       Mechanical Engineering Dept.
Mechanical Engineering Dept.   Ken Youssefi   14
Lance Armstrong’s 2-lb.
                                   Trek bike, 2004 Tour de
                                   France




     Pedestrian bridge in
    Denmark, 130 feet long
           (1997)



    Swedish Navy, Stealth
           (2005)

                                                             15
Ken Youssefi                 Mechanical Engineering Dept.
Higher Specific Strength (strength-to-weight ratio)
  Composites have a higher specific strength than many other materials. A
  distinct advantage of composites over other materials is the ability to use
  many combinations of resins and reinforcements, and therefore custom
  tailor the mechanical and physical properties of a structure.




The lowest properties for each material are associated with simple manufacturing
processes and material forms (e.g. spray lay-up glass fibre), and the higher
properties are associated with higher technology manufacture (e.g. autoclave
                                                                                 16
moulding of unidirectional glass fibre), the aerospace industry.
  Ken Youssefi                       Mechanical Engineering Dept.
Design flexibility
Composites have an advantage over other materials because they can be
molded into complex shapes at relatively low cost. This gives designers the
freedom to create any shape or configuration. Boats are a good example of
the success of composites.

Corrosion Resistance
Composites products provide long-term resistance to severe chemical and
temperature environments. Composites are the material of choice for
outdoor exposure, chemical handling applications, and severe environment
service.




                                                                              17
Ken Youssefi                    Mechanical Engineering Dept.
Low Relative Investment
One reason the composites industry has been successful is because of
the low relative investment in setting-up a composites manufacturing
facility. This has resulted in many creative and innovative companies in
the field.

Durability
Composite products and structures have an exceedingly long life span.
Coupled with low maintenance requirements, the longevity of composites is a
benefit in critical applications. In a half-century of composites development,
well-designed composite structures have yet to wear out.
In 1947 the U.S. Coast Guard built a series of forty-foot patrol boats,
using polyester resin and glass fiber. These boats were used until the
early 1970s when they were taken out of service because the design was
outdated. Extensive testing was done on the laminates after
decommissioning, and it was found that only 2-3% of the original strength
was lost after twenty-five years of hard service.
                                                                                 18
Ken Youssefi                     Mechanical Engineering Dept.
20% more fuel efficiency
                          and 35,000 lbs. lighter

                                                     19
Ken Youssefi   Mechanical Engineering Dept.
Composites are heterogeneous
       properties in composites vary from point to point in the material. Most
       engineering structural materials are homogeneous.

       Composites are highly anisotropic

       The strength in composites vary as the direction along which we
       measure changes (most engineering structural materials are isotropic).
       As a result, all other properties such as, stiffness, thermal expansion,
       thermal and electrical conductivity and creep resistance are also
       anisotropic. The relationship between stress and strain (force and
       deformation) is much more complicated than in isotropic materials.


    The experience and intuition gained over the years about the behavior of
    metallic materials does not apply to composite materials.



                                                                                  20
Ken Youssefi                       Mechanical Engineering Dept.
Composites materials are difficult to inspect with conventional ultrasonic,
    eddy current and visual NDI methods such as radiography.



American Airlines Flight 587, broke apart over
New York on Nov. 12, 2001 (265 people died).
Airbus A300’s 27-foot-high tail fin tore off.
Much of the tail fin, including the so-called
tongues that fit in grooves on the fuselage and
connect the tail to the jet, were made of a
graphite composite. The plane crashed
because of damage at the base of the tail that
had gone undetected despite routine
nondestructive testing and visual inspections.




                                                                                  21
 Ken Youssefi                      Mechanical Engineering Dept.
In November 1999, America’s Cup boat “Young America” broke in two due
    to debonding face/core in the sandwich structure.




                                                                            22
Ken Youssefi                    Mechanical Engineering Dept.

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Composites

  • 1. 1
  • 2. Muhammad Umair Bukhari Engr.umair.bukhari@gmail.com www.bzuiam.webs.com 03136050151
  • 3. A broad definition of composite is: Two or more chemically distinct materials which when combined have improved properties over the individual materials. Composites could be natural or synthetic. Wood is a good example of a natural composite, combination of cellulose fiber and lignin. The cellulose fiber provides strength and the lignin is the "glue" that bonds and stabilizes the fiber. Bamboo is a very efficient wood composite structure. The components are cellulose and lignin, as in all other wood, however bamboo is hollow. This results in a very light yet stiff structure. Composite fishing poles and golf club shafts copy this natural design. The ancient Egyptians manufactured composites! Adobe bricks are a good example. The combination of mud and straw forms a composite that is stronger than either the mud or the straw by itself. 3 Ken Yossefi
  • 4. Composites are combinations of two materials in which one of the material is called the reinforcing phase, is in the form of fibers, sheets, or particles, and is embedded in the other material called the matrix phase. Typically, reinforcing materials are strong with low densities while the matrix is usually a ductile or tough material. If the composite is designed and fabricated correctly, it combines the strength of the reinforcement with the toughness of the matrix to achieve a combination of desirable properties not available in any single conventional material. Components of composite materials Reinforcement: fibers Matrix materials Interface Glass Polymers Bonding Carbon Metals surface Organic Ceramics Boron Ceramic Metallic 4 Ken Youssefi Mechanical Engineering Dept.
  • 5. The essence of the concept of composites is that the load is applied over a large surface area of the matrix. Matrix then transfers the load to the reinforcement, which being stiffer, increases the strength of the composite. It is important to note that there are many matrix materials and even more fiber types, which can be combined in countless ways to produce just the desired properties. In the United States, composites manufacturing is a 25 billion dollar a year industry. There are about 6000 composites related manufacturing plants and materials distributors across the U.S. The industry employs more than 235,000 people. An additional 250,000 people are employed in businesses that support the composites industry, including materials suppliers, equipment vendors, and other support personnel. About 90% of all composites produced are comprised of glass fiber and either polyester or vinylester resin. Composites are broadly known as reinforced plastics. 5 Ken Youssefi Mechanical Engineering Dept.
  • 6. Composites Fibers Matrix materials Mechanical Engineering Dept. Ken Youssefi 6
  • 7. Polymer matrix composites (PMC) and fiber reinforced plastics (FRP) are referred to as Reinforced Plastics. Common fibers used are glass (GFRP), graphite (CFRP), boron, and aramids (Kevlar). These fibers have high specific strength (strength-to-weight ratio) and specific stiffness (stiffness-to-weight ratio) Matrix materials are usually thermoplastics or thermosets; polyester, epoxy (80% of reinforced plastics), fluorocarbon, silicon, phenolic. 7 Ken Youssefi Mechanical Engineering Dept.
  • 8. Reinforcing fibers Glass – most common and the least expensive, high strength, low stiffness and high density. GFRP consists 30-60% glass fibers by volume. Graphite (99% carbon) or Carbon (80-95% carbon) – more expensive than glass fibers, but lower density and higher stiffness with high strength. The composite is called carbon-fiber reinforced plastic (CFRP). Boron – boron fibers consist of boron deposited on tungsten fibers, high strength and stiffness in tension and compression, resistance to high temperature, but they are heavy and expensive. Aramids (Kevlar) – highest specific strength, toughest fiber, undergoes plastic deformation before fracture, but absorbs moisture, and is expensive. The average diameter of fibers used is usually less than .0004 inch (.01 mm). The tensile strength of a glass fiber could be as high as 650 ksi (bulk glass Su = 5-150 ksi) 8 Ken Youssefi Mechanical Engineering Dept.
  • 9. The mechanical properties of reinforced plastics vary with the kind, shape, relative volume, and orientation of the reinforcing material, and the length of the fibers. Effect of type, length, % volume, and orientation of fibers in a fiber reinforced plastic (nylon) Mechanical Engineering Dept. Ken Youssefi 9
  • 10. Phenolic as a matrix with asbestos fibers was the first reinforced plastic developed. It was used to build an acid-resistant tank. In 1920s it was Formica, commonly used as counter top., in 1940s boats were made of fiberglass. More advanced developments started in 1970s. Consumer Composites Typically, although not always, consumer composites involve products that require a cosmetic finish, such as boats, recreational vehicles, bathwear, and sporting goods. In many cases, the cosmetic finish is an in-mold coating known as gel coat. Industrial Composites A wide variety of composites products are used in industrial applications, where corrosion resistance and performance in adverse environments is critical. Generally, premium resins such as isophthalic and vinyl ester formulations are required to meet corrosion resistance specifications, and fiberglass is almost always used as the reinforcing fiber. Industrial composite products include underground storage tanks, scrubbers, piping, fume hoods, water treatment components, pressure vessels, and a host of other products. 10 Ken Youssefi Mechanical Engineering Dept.
  • 11. Advanced Composites This sector of the composites industry is characterized by the use of expensive, high-performance resin systems and high strength, high stiffness fiber reinforcement. The aerospace industry, including military and commercial aircraft of all types, is the major customer for advanced composites. These materials have also been adopted for use in sporting goods, where high-performance equipment such as golf clubs, tennis rackets, fishing poles, and archery equipment, benefits from the light weight – high strength offered by advanced materials. There are a number of exotic resins and fibers used in advanced composites, however, epoxy resin and reinforcement fiber of aramid, carbon, or graphite dominates this segment of the market. 11 Ken Youssefi Mechanical Engineering Dept.
  • 12. The metal matrix composites offer higher modulus of elasticity, ductility, and resistance to elevated temperature than polymer matrix composites. But, they are heavier and more difficult to process. 12 Ken Youssefi Mechanical Engineering Dept.
  • 13. Ceramic matrix composites (CMC) are used in applications where resistance to high temperature and corrosive environment is desired. CMCs are strong and stiff but they lack toughness (ductility) Matrix materials are usually silicon carbide, silicon nitride and aluminum oxide, and mullite (compound of aluminum, silicon and oxygen). They retain their strength up to 3000 oF. Fiber materials used commonly are carbon and aluminum oxide. Applications are in jet and automobile engines, deep-see mining, cutting tools, dies and pressure vessels. 13 Ken Youssefi Mechanical Engineering Dept.
  • 14. Mechanical Engineering Dept. Ken Youssefi 14
  • 15. Lance Armstrong’s 2-lb. Trek bike, 2004 Tour de France Pedestrian bridge in Denmark, 130 feet long (1997) Swedish Navy, Stealth (2005) 15 Ken Youssefi Mechanical Engineering Dept.
  • 16. Higher Specific Strength (strength-to-weight ratio) Composites have a higher specific strength than many other materials. A distinct advantage of composites over other materials is the ability to use many combinations of resins and reinforcements, and therefore custom tailor the mechanical and physical properties of a structure. The lowest properties for each material are associated with simple manufacturing processes and material forms (e.g. spray lay-up glass fibre), and the higher properties are associated with higher technology manufacture (e.g. autoclave 16 moulding of unidirectional glass fibre), the aerospace industry. Ken Youssefi Mechanical Engineering Dept.
  • 17. Design flexibility Composites have an advantage over other materials because they can be molded into complex shapes at relatively low cost. This gives designers the freedom to create any shape or configuration. Boats are a good example of the success of composites. Corrosion Resistance Composites products provide long-term resistance to severe chemical and temperature environments. Composites are the material of choice for outdoor exposure, chemical handling applications, and severe environment service. 17 Ken Youssefi Mechanical Engineering Dept.
  • 18. Low Relative Investment One reason the composites industry has been successful is because of the low relative investment in setting-up a composites manufacturing facility. This has resulted in many creative and innovative companies in the field. Durability Composite products and structures have an exceedingly long life span. Coupled with low maintenance requirements, the longevity of composites is a benefit in critical applications. In a half-century of composites development, well-designed composite structures have yet to wear out. In 1947 the U.S. Coast Guard built a series of forty-foot patrol boats, using polyester resin and glass fiber. These boats were used until the early 1970s when they were taken out of service because the design was outdated. Extensive testing was done on the laminates after decommissioning, and it was found that only 2-3% of the original strength was lost after twenty-five years of hard service. 18 Ken Youssefi Mechanical Engineering Dept.
  • 19. 20% more fuel efficiency and 35,000 lbs. lighter 19 Ken Youssefi Mechanical Engineering Dept.
  • 20. Composites are heterogeneous properties in composites vary from point to point in the material. Most engineering structural materials are homogeneous. Composites are highly anisotropic The strength in composites vary as the direction along which we measure changes (most engineering structural materials are isotropic). As a result, all other properties such as, stiffness, thermal expansion, thermal and electrical conductivity and creep resistance are also anisotropic. The relationship between stress and strain (force and deformation) is much more complicated than in isotropic materials. The experience and intuition gained over the years about the behavior of metallic materials does not apply to composite materials. 20 Ken Youssefi Mechanical Engineering Dept.
  • 21. Composites materials are difficult to inspect with conventional ultrasonic, eddy current and visual NDI methods such as radiography. American Airlines Flight 587, broke apart over New York on Nov. 12, 2001 (265 people died). Airbus A300’s 27-foot-high tail fin tore off. Much of the tail fin, including the so-called tongues that fit in grooves on the fuselage and connect the tail to the jet, were made of a graphite composite. The plane crashed because of damage at the base of the tail that had gone undetected despite routine nondestructive testing and visual inspections. 21 Ken Youssefi Mechanical Engineering Dept.
  • 22. In November 1999, America’s Cup boat “Young America” broke in two due to debonding face/core in the sandwich structure. 22 Ken Youssefi Mechanical Engineering Dept.