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The increasing use of composite materials in modern structures of high performance in automotive and aircraft structures calls for a deeper and more thorough knowledge of their properties. Composite materials are being used in an increasing number of products as more manufacturers discover the benefits of these versatile materials. Composites are an interesting class of materials for technological development, fulfilling the needs of numerous applications where the properties of current monolithic alloys are not adequate. However, cost and manufacturing feasibility and/or reliability have partially impaired the industrial application of these materials. In addition, how composite materials is desirable to have high wear resistance coupled with high bulk tenacity, in order to allow the component to absorb impact loads because of its enhanced mechanical and chemical properties, encompass many engineering problems. Following this concept, we will try to focus upon the following: The definition and concept behind composites as well as the necessity to use composites. The comparison of the structural and mechanical characteristics of the composites with those of conventional used materials. The study of processing of such materials and their viabilities with testing and some common as well as engineering examples.
Introduction
Most of the products we see every day are made from monolithic materials. That means the individual components consist of a single material (an unreinforced plastic), or a combination of materials that are combined in such a way that the individual components are indistinguishable (a metal alloy). Composite materials, on the other hand, consist of two or more materials combined in such a way that the individual materials are easily distinguishable.
1.1What makes a material a composite? A judicious combination of two or more materials that produces a synergistic effect. A material system composed of two or
more physically distinct phases whose combination produces aggregate and enhanced properties that are different from those of its constituents. Composite materials for construction, engineering, and other similar applications are formed by combining two or more materials in such a way that the constituents of the composite materials are still distinguishable, and not fully blended. One example of a composite material is concrete, which uses cement as a binding material in combination with gravel as a reinforcement. In many cases, concrete uses rebar as a second reinforcement, making it a three-phase composite, because of the three elements involved. Composite materials take advantage of the different strengths and abilities of different materials. In the case of mud and straw bricks, for example, mud is an excellent binding material, but it cannot stand up to compression and force well. Straw, on the
other hand, is well able to withstand compression without crumbling or breaking, and so it serves to reinforce the binding action of the mud. Humans have been creating composite materials to build stronger and lighter objects for thousands of years. The majority of composite materials use two constituents: a binder or matrix and a reinforcement. The reinforcement is stronger and stiffer, forming a sort of backbone, while the matrix keeps the reinforcement in a set place. The binder also protects the reinforcement, which may be brittle or breakable, as in the case of the long glass fibers used in conjunction with plastics to make fiberglass. Generally, composite materials have excellent compressibility combined with good tensile strength, making them versatile in a wide range of situations. Engineers building anything, from a patio to an airplane, look at the unique stresses that their construction will undergo. Extreme changes in temperature, external forces, and water or chemical erosion are all accounted for in an assessment of needs. When building an aircraft, for example, engineers need lightweight, strong material that can insulate and protect passengers while surfacing the aircraft. An aircraft made of pure metal could fail catastrophically if a small crack appeared in the skin of the airplane. On the other hand, aircraft integrating reinforced composite materials such as fiberglass, graphite, and other hybrids will be stronger and less likely to break up at stress points in situations involving turbulence. Many composites are made in layers or plies, with a woven fiber reinforcement sandwiched between layers of plastic or another similar binder. These composite materials have the advantage of being very moldable, as in the hull of a fiberglass boat. Composites have revolutionized a number of industries, especially the aviation industry, in which the development of higher quality composites allows companies to build bigger and better aircraft.
1.2. Composition :
MATRIX + REINFORCEMENT = COMPOSITE 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. Engineered composite materials must be formed to shape. The matrix material can be introduced to the reinforcement before or after the reinforcement material is placed into the mould cavity or onto the mould surface. The matrix material experiences a melding event, after which the part shape is essentially set. Depending upon the nature of the matrix material, this melding event can occur in various ways such as chemical polymerization or solidification from the melted state.
1.3Fibers: Fibers are a special case of reinforcements. They are generally continuous and have diameters ranging from 120 to
7400 pin (3-200 pm). Fibers are typically linear elastic or elastic-perfectly plastic and are generally stronger and stiffer than the same material in bulk form. The most commonly used fibers are boron, glass, carbon, and Kevlar.
1.4Matrix: The matrix is the binder material that supports, separates, and protects the fibers. It provides a path by which load
is both transferred to the fibers and redistributed among the fibers in the event of fiber breakage. The matrix typically has a
lower density, stiffness, and strength than the fibers. Matrices can be brittle, ductile, elastic, or plastic. They can have either linear or nonlinear stress-strain behavior. In addition, the matrix material must be capable of being forced around the reinforcement during some stage in the manufacture of the composite. Fibers must often be chemically treated to ensure proper adhesion to the matrix. The most commonly used matrices are carbon, ceramic, glass, metal, and polymeric. Each has special appeal and usefulness, as well as limitations.
1.5.2. The second level of classification refers to the reinforcement form - fibre reinforced composites, laminar composites and particulate composites. Fibre Reinforced composites (FRP) can be further divided into those containing discontinuous or continuous fibres.
1.5.3. Fiber Reinforced Composites are composed of fibers embedded in matrix material. Such a composite is considered to be a discontinuous fiber or short fiber composite if its properties vary with fiber length. On the other hand, when the length of the fiber is such that any further increase in length does not further increase, the elastic modulus of the composite, the composite is considered to be continuous fiber reinforced. Fibers are small in diameter and when pushed axially, they bend easily although they have very good tensile properties. These fibers must be supported to keep individual fibers from bending and buckling. 1.5.4. Laminar Composites are composed of layers of materials held together by matrix. Sandwich structures fall under this category. 1.5.5. Particulate Composites are composed of particles distributed or embedded in a matrix body. The particles may be flake s or in powder form. Concrete and wood particle boards are examples of this category.
The matrix must have mechanical strength with that of the reinforcement i.e. both should be compatible. Thus , if a high strength fiber is used as the reinforcement , there is no point using a low strength matrix, which will not transmit stress efficiently to the reinforcement.
Although the fabrication and application of composite materials by human being could be tracked back to ancient times conceptually, the technologies for fabricating composite materials or advanced composites we refereed to nowadays are young and still under development and improvement. Compared to conventional homogeneous materials (such as metals, plastics etc.), the manufacturing techniques for composite materials are more demanding and more sophisticated. There are variety of methods of practical interest are available one of them is mentioned below: 1.9.1 Filament winding method: This process is primarily used for hollow, generally circular or oval sectioned components, such as pipes and tanks. Fiber tows are passed through a resin bath before being wound onto a mandrel in a variety of orientations, controlled by the fiber feeding mechanism, and rate of rotation of the mandrel.
The relatively small demand, high initial investing on new manufacturing facilities, labor intensive and highly skilled workers needed for manufacturing composite, there is a strong need to identify and to develop low-cost composite materials with highspeed manufacturing technique. The other manufacturing techniques include: 1.9.2 Pultrusion: Pultrusion is a continuous molding process that combines fiber reinforcements and thermosetting resin.
1.9.3 Resin Transfer Molding (RTM): Resin Transfer Molding or RTM as it is commonly referred to is a Closed Mold Process in which reinforcement material is placed between two matching mold surfaces one being male and one being female.
Higher fatigue endurance limit (up to 60% of the ultimate tensile strength). 30-45% lighter than aluminium structures designed to the same functional requirements Composites are less noisy while in operation and provide lower vibration transmission than metals Composites are more versatile than metals and can be tailored to meet performance needs and complex design requirements The greatest advantage of composite materials is strength and stiffness combined with lightness. By choosing an appropriate combination of reinforcement and matrix material, manufacturers can produce properties that exactly fit the requirements for a particular structure for a particular purpose. Modern aviation, both military and civil, is a prime example. It would be much less efficient without composites. In fact, the demands made by that industry for materials that are both light and strong has been the main force driving the development of composites. It is common now to find wing and tail sections, propellers and rotor blades made from advanced composites, along with much of the internal structure and fittings. The airframes of some smaller aircraft are made entirely from composites, as are the wing, tail and body panels of large commercial aircraft. The right composites also stand up well to heat and corrosion. This makes them ideal for use in products that are exposed to extreme environments such as boats, chemical-handling equipment and spacecraft. In general, Another advantage of composite materials is that they provide design flexibility. Composites can be molded into complex shapes a great asset when producing
The downside of composites is usually the cost. Although manufacturing processes are often more efficient when composites are used, the raw materials are expensive. Composites will never totally replace traditional materials like steel, but in many cases they are just what we need. And no doubt new uses will be found as the technology evolves. We havent yet seen all that composites can do.
Complex double curvature parts with smooth surface finish can be made in one manufacture operation. High resistance to impact damage Like metals thermoplastics have indefinite shelf life. Composites are dimensionally stable as they have low coefficient of thermal expansion. The improved weatherability of composites in marine environment as well as their corrosion resistance and reduce the down time for maintenance.
Items such as the wings and tail of an aircraft as well as the propellers and rotors are often made from composites. These materials hold up under a wide range of temperatures and are highly resistant to rust and corrosion. In terms of aesthetics, many composite materials used in aircraft construction are easy to shape and mold to fit design and engineering plans. 1.12.3 Sports:
A number of different sports products include composite-based components. Many modern baseball bats are either made entirely from metal or wood composites or include a composite handle to resist breakage. Golf and tennis manufacturers also rely on composites to improve strength and reduce weight in clubs and rackets. Other sporting equipment, including surfboards and skis, contains composite materials that add flexibility while maintaining durability. 1.12.4Boating: Many modern boats are made from composite materials such as fiberglass or thermoplastics. While traditional wooden boats were subject to rot or warping over time, and metal boats were heavy and likely to rust, composites offer superior performance and reduced maintenance. They are lightweight enough to stay afloat, yet strong enough to resist punctures and cracking. Most composite boats are unlikely to corrode, even after frequent exposure to salt water and sea air. In addition to racing and pleasure boats, composite materials are used on kayaks, canoes and jet skis. 1.12.5Ballistic Protection Carbon-based composite fibers are often used to make bulletproof vests and other ballistic protection devices. These fibers, including Kevlar, produce fairly lightweight body armor options that offer effective protection from bullets, flames and some explosives.
According to the Massachusetts Institute of Technology, Kevlar is five times stronger than steel and yet only half as dense as fiberglass. Along with other composite fibers, Kevlar has saved thousands of lives and revolutionized protective gear for lawn enforcement and military personnel.
"The future is in composites" is the realization of many decades of high-technology progress toward different materials and parts assembled and combined as monolithic units that would provide a combination of versatility, strength and other properties beyond the possibilities of conventional materials like metal, wood or concrete. Future business opportunities due to strong developmental activities focusing primarily on products & processes need to be pursued in India. Towards such an objective, a multi-agency approach involving the industry, Government, academia, research laboratory, certification/standardization and user agencies would be required for a quantum jump in composite technology in the country.
1.15 Conclusion:
Due to their reduced weight, composite materials have an advantage over conventional metallic materials; although, currently it is expensive to fabricate composites. Until techniques are introduced to reduce initial implementation costs and address the issue of non-biodegradability of current composites, this relatively new material will not be able to completely replace traditional metallic alloys. Who knows where technology will take us in future!!! only time is eligible candidate for this question .
Acknowledgement :
We would like to acknowledge with appreciation the numerous and valuable comments, suggestions, constructive criticisms and proper guidance from the following faculty of the mechanical engineering department of our college: [1] prof. vasant jog [2] prof. anand khandekar .