I.

Phases of composite materials types and functions

ALENA SIKOV
TECHNICAL UNIVERSITY OF KOICE CIVIL ENGINEERING FACULTY DEPARTMENT OF MATERIAL ENGINEERING

LLP ERASMUS - IP 2012, PRAGUE

Definition of the composite material

A multiphase material formed from a combination of materials which differ in composition or form, remain bonded together, and retain their identities and properties. Composites maintain an interface between components and act in concert to provide improved specific or synergistic characteristics not obtainable by any of the original components acting alone

Synergistic effect
QK = Q(A) + Q(B) + Q(C) + Q(A) . Q(B) . Q(C)
sum effect synergistic effect

where: QK; Q(A); Q(B); Q(C) quality of composite / components A, B, C contain of components Synergistic effect is one of the objective characteristics differentiating the composite materials from the other ones

Phases of a composite material

Phase is: a region of matter that possesses uniform intensive properties throughout its volume a homogeneous area of composite material

Discontinuous phase (stiffer and stronger) - filler / reinforcement, Continuous phase (less stiff and weaker) binder / matrix Interphase between matrix and reinforcement

Roles of phases
Matrix
surrounds and supports other constituents by keeping their relative positions and holding them together, protects both the reinforcement and whole the composite from environment effects/deterioration; transfers the loading to reinforcement
protects the filler from abrasion (with each other) enhances some of the properties of the resulting material (that filler alone is not able to impart). These properties are such as:
transverse strength of a lamina impact resistance

Filler
imparts special properties, such as electrical and mechanical, to improve the matrix properties, provides some stiffening and strenghtening of the material, provides control of cracks rise and development

provides better finish to final product

Systems of composite materials based on ratio of individual phases

1st limiting system
matrix

Vc = Vm

filler

matrix

Composite of I. type Vc = Vm + Vf Filler is dispersed Vf can increase at the cost of Vm up to maximal possible fillig of volume 2 nd limiting system Vc = Vm + Vf Closest packing of volume by filler

Composite of II. type Vc = Vf + Vm + Vv Changing the ratio of phases is possible only by reduction of matrix and incorporation of voids instead Discrete voids

Composite of III. type Vc = Vf + Vm + Vv Volume of voids increases, voids start to be continuous

3 rd limiting system Vc = Vv + Vf Without matrix Composite is incoherent, loose

Parameters influencing resulting properties of a composite material

Volume (or weight) fraction of phases Shape, geometry, and distribution of the phases Orientation of filler/reinforcement in system (isothropy/anisothropy) Individual properties of phases, compatibility of components Bonding strength/ITZ (interfacial transition zone) properties on the interface between the dispersed phase and matrix Interaction of composite and ambient environment Age of composite components Production technology

Filler/reinforcement
Forms:
Particles Flakes Fibers

Filler/reinforcement Isotropic

Orientation
Anisotropic
Not isotropic; having mechanical and/or physical properties which vary with direction relative to natural reference axes inherent in the material

Having uniform properties in all directions. The measured properties of an isotropic material are independent of the axis of testing.

Classification of composite materials based on the form and orientation of filler/reinforcement

Filler/reinforcement -

Particles

They usually reinforce a composite equally in all directions. Particle fillers are usually of very small dimension (0,01 0,1 m) and they occupy app. 15% of composite volume they are dispersed without mutual connection Typical particles in the terms of construction composite materials are of bigger dimensions (granularity), such as sand and gravel

Usual materials of particle fillers

Natural rocks: granit, feldspar, silica, limestone, gypsum, kaoline ... Glass microspheres, milled glass Metal particles Ceramic particles

Filler/reinforcement -

Flakes

because of their shape, usually reinforce in 2-D. Two common flake materials are glass and mica.

Filler/reinforcement -

Fibers

Natural Fibres:
Animal fibres: Silk, Wool, Spider silk, Sinew, Camel hair Vegetable fibres: Cotton, Jute, Bamboo, Sisal, Maze, Hemp, Sugarcane, Banana, Ramie, Kapok, Coir, Abaca, Kenaf, Flax, Raffia palm

Processed Fibres:
Mineral fibres: Asbestos, Basalt, Glass Metal fibers: steel Polymer fibers: PE, PP, PVA ...

Advanced fibres: fibres possessing high specific

strength [/]) Glass Carbon Organic: aramid, kevlar Ceramic: borone, silicone

Filler/reinforcement - Fibers

Performance properties of fibers

High tensile strength Specific modulus of elasticity Stability in actual matrix Shape Surface treatment End treatment/shape Lenght and diameter aspect ratio (large aspect ratios result in stronger composites, but they are more difficult to process)

Filler/reinforcement - Fibers

Forms of Fibrous Composites

Single-layered composites:
continious (Layer, Lamina, Ply - any of the term is used)

unidirectional

bi-directional

discontinuous

random orientation

preferred orientation

Multi-layered composites: Laminates

Hybrides

Filler/reinforcement - Fibers

Kinds of fibers
Steel
The usual way of application is as short fibers to random reinforcement of concrete they are made of cold drawn steel wire with low content of carbon various shapes and endings (hooked, undulated or flat) are produced in order to obtain correct anchorage in concrete

Polypropylene
They are produced in two types: as fibrillated ones (bundles of several fibers) cut from a sheet; or monofilaments cut from a yarn

Monofilaments

Fibrillated fibers

Glass
manufactured from molten glass, from which glass monofilaments are drawn and then gathered to strands. The strands are used for preparation of different glass fiber products (yarns, rovings, woven fabrics, mats)

Carbon
They are commonly produced by the pyrolysis of hydrocarbon precursors in a non-reactive atmosphere carbon fibers offer high strength, high stiffness, low density, and low thermal expansion not achievable with any other structural fibers. In addition, carbon fibers have high thermal and electrical conductivity which make them suitable for specialized applications where thermal energy and electrical current need to be specifically controlled

Carbon fibers allow to produce a composites with excellent strength and stiffness and reduced weight

The role of fibres in cementitious materials is that they generally have two positive effects:
reduction of shrinkage strains in early age of concrete, when high risk of shrinkage cracks formation comes fibers with lower modulus of elasticity are sufficient carrying the stresses caused by external loads fibers with higher modulus of elasticity are required

Filler/reinforcement - Fibers

Properties of selected types

Type Steel Polypropylene Glass Carbon

Diameter [mm] 0,1 - 1,0 0,02 - 0,4 0,05 - 0,15 0,008 - 0,01

Tensile Density strength [g/cm3] [GPa] 7,8 0,9 2,5 1,9 0,3 - 2,0 0,3 - 0,5 1,0 - 3,0 1,0 - 3,0

Modulus Ultimate of elongation elasticity [%] [GPa] 200 0,5 - 3,5 5 15 - 25 70 - 80 230 - 400 1,5 - 4,5 0,5 - 1,0

Matrix
The primary consideration in the selection of a matrix is its basic mechanical properties. For high-performance composites, the most desirable mechanical properties of a matrix are: High modulus of elasticity, which influences the compressive strength of the composite High tensile strength, which controls the intraply cracking in a composite laminate High fracture toughness, which controls ply delamination and crack growth

Matrix

Usual materials

Plastics Metals Ceramics

Matrix Usual materials -

Plastics

Thermoplastics:
polypropylene, polyvinyl chloride (PVC), nylon, polyurethane, poly-ether-ether ketone (PEEK), polyphenylene sulfide (PPS), polysulpone

Matrix Usual materials -

Plastics

Thermoplastics are increasingly used over thermosets becuase of the following reasons: Processing is faster than thermoset composites since no curing reaction is required. Thermoplastic composites require only heating, shaping and cooling. Better properties: high toughness (delamination resistance) and damage tolerance, low moisture absorption chemical resistance They have low toxity Cost is high

Matrix Usual materials -

Plastics

Thermosets:
polyesters epoxies polyimides other resins

Matrix Usual materials - Plastics

Properties of selected types

Epoxy Modulus of elasticity Em (MPa) Shear modulus of elasticity Gm (MPa) Tensile strength pm (MPa) Density (kg.m-3) Maximal temperature Tmax (oC) 4 500 1 600 130 1 200 90 -200 Polyester 4 000 1 400 80 1 200 60 - 100 Phenolic 3 000 1 100 70 1 300 120 - 200 Polyamid 4 000 19000 1 100 70 1 400 250 - 300

Matrix Usual materials -

Metals

Aluminum Titanium Copper

Matrix Usual materials -

Ceramics

Carbon Silicon carbide Silicon nitride Lime, gypsum, cement

Phase boundary - interfacial transition zone

Thin region in which the intensive properties change discontinuously. Usually the properties of boundary are worse as those of separate phases. At all kinds of composites there is a critical area, with the highest probability of cracks and failure all of composite. It is the weakest area of composite material Good bonding (adhesion) between matrix phase and dispersed phase provides better transfer of load

Character of ITZ is influenced and can be optimized by:

physical properties of particles/fibers (specific surface area, surface coarseness, porosity, ), chemical processes - reaction between matrix and filler technological processes: mixing, compacting, forming, curing of composite

Interfacial transition zone

Ways of modification
In cementitious CM 1. Through aggregate quality:
optimal grading (means grading with minimal void ratio. It can be reached using aggregates of various grain size) surface area - minimal shape - regular surface - coarse

2. Through matrix quality:

porosity, cracks and hydratation products control due to minimal water/cement ratio and additive fine-grain materials (granulated blast furnace slag, fly ash, microsilica)

Role of mineral fine-grain materials:

improvement in packing, that is, action as a filler with much more smaller particles than cement particles better adhesion of matrix
aggregate

In polymer CM:
aggregate must be of good quality, free of dust and other debris, and dry. failure of these criteria can reduce the bond strength between the polymer binder and the aggregate. bonding can be improved by some special chemical admixtures

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