Composite Material Defined A materials system composed of two or more physically distinct phases whose combination produces aggregate

e properties that are different from those of its constituents

3. Polymer Matrix Composites (PMC) - thermosetting resins are widely used in PMC Examples: epoxy and polyester with fiber reinforcement,and phenolic with powders Functions of the Matrix Material(Primary Phase) Provides the bulk form of the part or product made of the composite material Holds the imbedded phase in place, usually enclosing and often concealing it When a load is applied, the matrix shares the load with the secondary phase, in some cases deforming so that the stress is essentially born by the reinforcing agent The Reinforcing Phase (Secondary Phase) Function is to reinforce the primary phase Imbedded phase is most commonly one of the following shapes: Fibers Particles Flakes In addition, the secondary phase can take the form of an infiltrated phase in a skeletal or porous matrix

Advantages Composites can be very strong and stiff, yet very light in weight, so ratios of strength-toweight and stiffness-to-weight are several times greater than steel or aluminum Fatigue properties are generally better than for common engineering metals Toughness is often greater too Composites can be designed that do not corrode like steel Possible to achieve combinations of properties not attainable with metals, ceramics, or polymers alone

Components in a Composite Material Nearly all composite materials consist of two phases: 1. Primary phase - forms the matrix within which the secondary phase is imbedded 2. Secondary phase - 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

Example: a powder metallurgy part infiltrated with polymer

Classification Scheme for Composite Materials 1. Metal Matrix Composites (MMC) - mixtures of ceramics and metals, such as cemented carbides and other cermets 2. Ceramic Matrix Composites (CMC) Al2O3 and SiC imbedded with fibers to improve properties, especially in high temperature applications The least common composite matrix Fibers Filaments of reinforcing material, usually circular incross-section Diameters range from less than 0.0025 mm to about 0.13 mm, depending on material Filaments provide greatest opportunity for strength enhancement of composites 1

 The filament form of most materials is significantly stronger than the bulk form As diameter is reduced, the material becomes oriented in the fiber axis direction and probability of defects in the structure decreases significantly

The distribution of particles in the composite matrix is random, and therefore strength and other properties of the composite material are usually isotropic Strengthening mechanism depends on particle size The Interface There is always an interface between constituent phases in a composite material For the composite to operate effectively, the phases must bond where they join at the interface

Continuous vs. Discontinuous Fibers Continuous fibers - very long; in theory, they offer a continuous path by which a load can be carried by the composite part Discontinuous fibers (chopped sections of continuous fibers) short lengths (L/D = roughly 100) Important type of discontinuous fiber are whiskers hair like single crystals with diameters down to about 0.001 mm (0.00004 in.) with very high strength Fiber Orientation Three Cases One-dimensional reinforcement, in which maximum strength and stiffness are obtained in the direction of the fiber Planar reinforcement, in some cases in the form of a two-dimensional woven fabric Random or three-dimensional in which the composite material tends to possess isotropic properties Interphase In some cases, a third ingredient must be added to achieve bonding of primary and secondary phases Called an interphase, this third ingredient can be thought of as an adhesive Properties are Determined by Three Factors: 1. The materials used as component phases in the composite 2. The geometric shapes of the constituents and resulting structure of the composite system Particles and Flakes A second common shape of imbedded phase is particulate, ranging in size from microscopic to macroscopic Flakes are basically two-dimensional particles - small flat platelets 2 3. The manner in which the phases interact with one another

The assumption of an isostress state :

Computing composite properties Determine the mechanical property of Continuous and Aligned Fiber composites Longitudinal direction Fc =Fm + Ff The assumption of an isostrain state :

Determine the mechanical property of Discontinuous and Aligned Fiber Composites If the fiber length (l) is less than critical(lc), the longitudinal strength

If (l >lc), the longitudinal strength

Where

The ratio of the load carried by the fibers to that carried by the matrix is

Determine the mechanical property of Discontinuous and Randomly Oriented Fiber Composites

Transverse Loading 3

Principal fiber materials in FRPs are glass, carbon, and Kevlar 49 Less common fibers include boron, SiC, and Al2O3, and steel Glass (in particular E-glass) is the most common fiber material in today's FRPs; Metal Matrix Composites (MMCs) A metal matrix reinforced by a second phase Reinforcing phases: 1. Particles of ceramic (these MMCs are commonly called cermets)

Where K = fiber efficiency parameter EXAMPLE PROBLEM A continuous and aligned glass fiberreinforced composite consists of 40 vol% of glass fibers having a modulus of elasticity of 69 GPa and 60 vol% of a polyester resin that, when hardened, displays a modulus of 3.4 GPa. = 0.1 -0.6.

(a) Compute the modulus of elasticity of this composite in the longitudinaldirection. (b) If the cross-sectional area is 250 mm 2 and a stress of 50 MPa is applied in this longitudinal direction, compute the magnitude of the load carried by each of the fiber and matrix phases. (c) Determine the strain that is sustained by each phase when the stress inpart (b) is applied. Polymer Matrix Composites (PMCs) A polymer primary phase in which a secondary phase is imbedded as fibers, particles, or flakes Commercially, PMCs are more important than MMCs or CMCs Examples: most plastic molding compounds, rubber reinforced with carbon black, and fiberreinforced polymers (FRPs) Fiber-Reinforced Polymers (FRPs) A PMC consisting of a polymer matrix imbedded with high-strength fibers Polymer matrix materials: Usually a thermosetting (TS) plastic such as unsaturated polyester or epoxy Can also be thermoplastic (TP), such as nylons (polyamides), polycarbonate, polystyrene, and polyvinylchloride Fiber reinforcement is widely used in rubber products such as tires and conveyor belts Fibers in PMCs Various forms: discontinuous (chopped), continuous, or woven as a fabric

2. Fibers of various materials: other metals, ceramics, carbon, and boron Cemented Carbides One or more carbide compounds bonded in a metallic matrix Common cemented carbides are based on tungsten carbide(WC), titanium carbide (TiC), and chromium carbide(Cr3C2) Tantalum carbide (TaC) and others are less common Metallic binders: usually cobalt (Co) or nickel (Ni)

Cerami c Matrix Composites (CMCs) A ceramic primary phase imbedded with a secondary phase, which usually consists of fibers Attractive properties of ceramics: high stiffness, hardness, hot hardness, and compressive strength; and relatively low density Weaknesses of ceramics: low toughness and bulk tensilestrength, susceptibility to thermal cracking CMCs represent an attempt to retain the desirable properties of ceramics while compensating for their weaknesses 4