Composites: Many Engineering Components Are Composites

MSE 406: Thermal and Mechanical Behavior of Materials D.D.
Johnson 2005
Composites
Many engineering components are composites
MSE 406: Thermal and Mechanical Behavior of Materials D.D. Johnson 2005
Composites
ISSUES TO ADDRESS...
What are the classes and types of composites?
Why are composites used instead of metals,
ceramics, or polymers?
How do we estimate composite stiffness & strength?
What are some typical applications?
Classification of Composites
Composites:
- Multiphase material w/significant
proportions of ea. phase.
Matrix:
- The continuous phase
- Purpose is to:
transfer stress to other phases
protect phases from environment
- Classification: MMC, CMC, PMC
Dispersed phase:
-Purpose: enhance matrix properties.
MMC: increase oy, TS, creep resist.
CMC: increase Kc
PMC: increase E, oy, TS, creep resist.
-Classification: Particle, fiber, structural
metal ceramic polymer
From D. Hull and T.W. Clyne, An Intro to Composite
Materials, 2nd ed., Cambridge University Press, New
York, 1996, Fig. 3.6, p. 47.
Particle-reinforced
Examples:
Adapted from Fig.
10.10, Callister 6e.
Adapted from Fig.
16.4, Callister 6e.
Adapted from Fig.
16.5, Callister 6e.
COMPOSITE SURVEY: Particle-I
Elastic modulus, E
c
, of composites:
-- two approaches.
Application to other properties:
-- Electrical conductivity, oe: Replace E by oe.
-- Thermal conductivity, k: Replace E by k.
Particle-reinforced
From Fig. 16.3,
Callister 6e.
COMPOSITE SURVEY: Particle-II
Aligned Continuous fibers
Fiber-reinforced
Particle-reinforced Structural
Ex:
From W. Funk and E. Blank, Creep deformation of
Ni3Al-Mo in-situ composites", Metall. Trans. A Vol.
19(4), pp. 987-998, 1988.
--Metal: '(Ni
3
Al)-o(Mo)
by eutectic solidification.
--Glass w/SiC fibers
formed by glass slurry
E
glass
= 76GPa; E
SiC
= 400GPa.
From F.L. Matthews and R.L.
Rawlings, Composite Materials;
Engineering and Science, Reprint
ed., CRC Press, Boca Raton, FL,
2000. (a) Fig. 4.22, p. 145 (photo
by J. Davies); (b) Fig. 11.20, p.
349 (micrograph by H.S. Kim, P.S.
Rodgers, and R.D. Rawlings).
(a)
(b)
COMPOSITE SURVEY: Fiber-I
Discontinuous, random 2D fibers
Fiber-reinforced
Example: Carbon-Carbon
--process: fiber/pitch, then
burn out at up to 2500C.
--uses: disk brakes, gas
turbine exhaust flaps, nose
cones.
Other variations:
--Discontinuous, random 3D
--Discontinuous, 1D
fibers lie
in plane
view onto plane
C fibers:
very stiff
very strong
C matrix:
less stiff
less strong
(b)
(a)
COMPOSITE SURVEY: Fiber-II
Chapter 6: Elasticity of Composites
Stress-strain response depends on properties of
reinforcing and matrix materials (carbon, polymer, metal, ceramic)
volume fractions of reinforcing and matrix materials
orientation of fibre reinforcement (golf club, kevlar jacket)
size and dispersion of particle reinforcement (concrete)
absolute length of fibres, etc.
concentration size shape
distribution
orientation
Families of Composites:
particle, fibre, structural reinforcements
Orientation dependence
Twisting,
Bending
ceramics
Isostrain: Load & Reinforcements Aligned

Isoload: Load & Reinforcements Perpendicular
(Isostress below)
Two simplest cases: Iso-load and Iso-strain
Strain or elongation of matrix
and fibres are the same!
Load (Stress) across matrix
and fibres is the same!
F
F
F
F
E
c
= E
o
o=1,N

V
o
1
E
c
=
o=1,N

V
o
E
o

V
o
=
V
o
V
Tot
Volume fraction
Iso-strain Case in Ideal Composites
Isostrain Case:
F
c
=F
m
+F
r
c
c
=c
m
=c
r strain
forces
F
F
Composite Property:
P
c
= P
o
o=1,N

V
o
Properties include: elastic moduli, density, heat capacity,
thermal expansion, specific heat, ...
*like law of mixtures
Load is distributed over matrix and fibers, so o
c
A
c
= o
m
A
m
+ o
f
A
f
.

o
c
=o
m
(A
m
/Ac)+o
f
(A
f
/Ac)
or o
c
=o
m

V
m
+o
f

V
f
*if the fibers are continuous,
then volume fraction is easy.
For Elastic case:

o
c
=c
c
E
c
=c
m
E
m

V
m
+c
f
E
f

V
f
=c
c
(E
m

V
m
+E
f

V
f
)
Composite Property:
P
c
= P
o
o=1,N

V
o
density,

heat capacity,

thermal expansion,
*like law of mixtures
For Elastic case:

o
c
=c
c
E
c
=c
m
E
m

V
m
+c
f
E
f

V
f
=c
c
(E
m

V
m
+E
f

V
f
)
Consider Density, Heat Capacity, and Thermal Expansion

c
=
o o =1,N

V
o
N =2

1

V
1
+
2

V
2

C
c
=
C
1
1

V
1
+C
2

2

V
2
1

V
1
+
2

V
2

o
c
=
o
1
E
1

V
1
+o
2
E
2

V
2
E
1

V
1
+E
2

V
2
How?

c
c
=
o
c
E
c
o
c
=
dc
c
dT
=
d
dT
o
c
E
c
|
\

|
.
| =
1
E
c
do
c
dT
=
(dc
1
/dT)E
1

V
1
+(dc
2
/dT)E
2

V
2
E
c
=
o
1
E
1

V
1
+o
2
E
2

V
2
E
1

V
1
+E
2

V
2
Need to assess the proper dependence of the properity to get Rule-of-Mixture correct.
Iso-Load Case for Ideal Composites
Isoload Case:
F
c
=F
m
=F
r
c
c
=c
m
+c
r strain
forces
Composite Property
1
P
c
=
o=1,N

V
o
P
o
Properties include: elastic moduli, density, heat capacity,
thermal expansion, specific heat, ...
*like resistors in parallel.
Without de-bonding, loads are equal, therefore, strains must add, so

c
c
=c
m

V
m
+c
f

V
f
=
o
E
m
|
\

|
.
|
|
|
|
|

V
m
+
o
E
f
|
\

|
.
|
|
|
|
|

V
f
*if the fibers are continuous
or planar, then area of
applied stress is the same. elastic case
ISOSTRAIN Example

Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre
reinforcements of glass (E = 76 GPa).

What is Elastic Modulus?
E
c
=

V
m
E
m
+

V
f
E
f
=(1

V
f
)E
m
+

V
f
E
f
~

V
f
E
f
= 26.7 GPA
* Stiffness of composite under isostrain is dominated by fibres.
~ 25 GPA
ISOLOAD Example

Suppose a polymer matrix (E= 2.5 GPa) has 33% fibre
reinforcements of glass (E = 76 GPa).

What is Elastic Modulus?
1
E
c
=

V
m
E
m
+

V
f
E
f
E
C
=
E
m
E
f

V
f
E
m
+(1

V
f
)E
f
~
E
m
(1

V
f
)
Rearrange:
= 3.8 GPA
* Elastic modulus of composite under isoload condition
Strongly depends on stiffness of matrix, unlike isostrain
case where stiffness dominates from fibres.
isostrain
isoload
Particle reinforcements usually fall in between two extremes.
Modulus of Elasticity in Tungsten Particle Reinforced Copper
Simplified Examples of Composites
Are these isostrain or isoload?

What are some real life examples?
Critical fiber length for effective stiffening & strengthening:
Fiber-reinforced

fiber length > 15
o
f
d
t
c
fiber diameter
shear strength of
fiber-matrix interface
fiber strength in tension
Ex: For fiberglass, fiber length > 15mm needed
Why? Longer fibers carry stress more efficiently!

fiber length > 15
o
f
d
t
c
Shorter, thicker fiber:

fiber length < 15
o
f
d
t
c
Longer, thinner fiber:
Poorer fiber efficiency Better fiber efficiency
Adapted from Fig.
16.7, Callister 6e.
COMPOSITE SURVEY: Fiber-III
Estimate of Ec and TS:
--valid when

-- Elastic modulus in fiber direction:

--TS in fiber direction:
efficiency factor:
--aligned 1D: K = 1 (anisotropic)
--random 2D: K = 3/8 (2D isotropy)
--random 3D: K = 1/5 (3D isotropy)
Fiber-reinforced

fiber length > 15
o
f
d
t
c

E
c
= E
m
V
m
+KE
f
V
f

(TS)
c
= (TS)
m
V
m
+(TS)
f
V
f
(aligned 1D)
Values from Table 16.3, Callister 6e.
COMPOSITE SURVEY: Fiber-IV
Structural
Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0/90
-- benefit: balanced, in-plane stiffness
Sandwich panels
-- low density, honeycomb core
-- benefit: small weight, large bending stiffness
Adapted from
Fig. 16.16,
Callister 6e.
Adapted from Fig. 16.17,
Callister 6e.
COMPOSITE SURVEY: Structural
CMCs: Increased toughness PMCs: Increased E/
MMCs:
Increased
creep
resistance
Adapted from T.G. Nieh, "Creep rupture of a
silicon-carbide reinforced aluminum
composite", Metall. Trans. A Vol. 15(1), pp.
139-146, 1984.
Composite Benefits
Laminate Composite (Ideal) Example
Gluing together these composite layers
composed of epoxy matrix (E
m
= 5 GPa)
with graphite fibres (E
f
= 490 GPa and
V
f
= 0.3). Central layer is oriented 90
0

from other two layers.
Case I - Load is applied parallel to fibres in outer two sheets.
Case II - Load is applied parallel to fibres of central sheet.
What are effective elastic moduli in the two case?
First need to know how individual sheets respond, then average.
1
E
=
0.3
490GPa
+
0.7
5GPa
E
=7.1GPa
For isoload case.
E
||
=0.3(490GPa)+0.7(5GPa)E
||
=150.5GPa
For isotrain case.
Case I: E
lam
=(2/3)(150.5 GPa) + (1/3)(7.1 GPa) = 102.7 GPa
Case II: E
lam
=(1/3)(150.5 GPa) + (2/3)(7.1 GPa) = 54.9 GPa
Mechanical Response of Laminate is Complex and NOT Ideal
3 Conditions required: consider top and bottom before laminated
strain compatibility- top and bottom must have same strain when glued.
stress-strain relations - need Hookes Law and Poisson effect.
equilibrium - forces and torques, or twisting and bending.
Isostrain for load
along x-dir:
Poisson Effect and
Displacements in A:
When glued together displacements have to be same!
Unequal displacements not allowed!
So, top gets wider (o
y
top
> 0) and bottom gets narrower (o
y
bott
< 0).

Equilibrium: F
y
= 0 = (o
y
bot
t
bot
+ o
y
top
t
top
)L. (t = thickness)
o
x
top
=
E
top
E
bott
o
x
bott
A
y
top
=
E
top
E
bott
A
y
bott
COMPATIBILITY: When glued, displacements have to be same!
As stress is applied, compatibility can be maintained, depending on the
laminate, only if materials twists.
Symmetry of laminate composite dictates properties
Elastic constants are different for different symmetry laminates.
Orientation of layers dictates response to stresses
Want compressive stresses at end of
laminate so there are no tensile stresses to
cause delamination - failure!
NO delamination - failure!
Apply in-pane Tensile Stress
A B
+90 +45
+45 45
45 +90
45 +90
+45 45
+90 +45
Tensile -> delaminate
Compressive
Why Laminate Composite is NOT Ideal
Depending on placement of load and the orientation of fibres
internal to sheet and the orientation of sheets relative to one
another, the response is then very different.

Examples of orientations of laminated sheets that provided
compressive stresses at edges of composite and also tensile
stresses there. >>>> Tensile stresses lead to delamination!

The stacking of composite sheets and their angular orientation
can be used to prevent twisting moments but allow bending
moments. This is very useful for airplane wings, golf club shafts
(to prevent slices or hooks), tennis rackets, etc., where power
or lift comes or is not reduced from bending.
Thermal Stresses in Composites
Not just due to fabrication, rather also due to thermal expansion differences
between matrix and reinforcements o
T
m
and o
T
r
.

Thermal coatings, e.g.

Material with most contraction (least) has positive (negative) residual
stress. (For non-ceramics, you should consider plastic strain too.)

Ceramic-oxide thermal layers, e.g. on gas turbine engines:
ceramic coating ZrO
2
-based (lower o
T
r
)
metal blade (Ni
x
Co
1-x
)CrAlY (higher o
T
m
)

Failure by delamination without a good design of composite, i.e.
compatibility maintained.

o ~| o
T
m
o
T
r
| ATE =Ao
T
ATE
c
At T
1

At T
2

If compatible,
composite will
bend and rotate
Composites are classified according to:
-- the matrix material (CMC, MMC, PMC)
-- the reinforcement geometry (particles, fibers, layers).
Composites enhance matrix properties:
-- MMC: enhance o
y
, TS, creep performance
-- CMC: enhance K
c
-- PMC: enhance E, o
y
, TS, creep performance
Particulate-reinforced:
-- Elastic modulus can be estimated.
-- Properties are isotropic.
Fiber-reinforced:
-- Elastic modulus and TS can be estimated along fiber dir.
-- Properties can be isotropic or anisotropic.
Structural:
-- Based on build-up of sandwiches in layered form.
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MSE 406: Thermal and Mechanical Behavior of Materials D.D.

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