MSE 280: Introduction to Engineering Materials

Composites
Reading: Callister Ch. 15

Issues to address I dd What are composites? Classification of composites. Why composites? Mechanical properties of composites. Applications.
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Composites: definition & examples

- Multiphase materials with chemically different phases and distinct interfaces. - Properties of the resultant combination of materials are superior to the properties of the individual components. - Advantages: High-strength/light-weight, low cost, environmentally resistant - Natural composites:
-Wood: strong & flexible cellulose fibers in stiffer lignin (surrounds the fibers). -Bone B : strong t but b t soft ft collagen ll (protein) ( t i ) within ithi hard h d but b t brittle b ittl apatite tit (mineral). -Certain types of rocks can also be considered as composites.

-Synthetic composites: fiberglass, concrete, carbon-carbon composites.

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Bicycle forks
Braided and unidirectional S-2 Glass and carbon fibers are used to produce forks with different stiffness

High Strength Weight Reduction Design Flexibility Cost Performance

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From http://matse101.mse.uiuc.edu/

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Pole-vaulting
Lightweight g t eg t Buckling resistance Strong Minimal twisting Cost - low o density de s ty - stiffness - yield strength

Longitudinal carbon fibers/epoxy

Glass fiber web/epoxy

Glass fiber rings

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From http://matse101.mse.uiuc.edu/

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Boeing 757-200
Flap support fairings Fwd segment (graphite/Kevlar + non-woven Kevlar mat Aft segment (graphite/fiberglass) Ailerons (graphite) Engine strut fairings (Kevlar/fiberglass) Environmental control system ducts (Kevlar) Aft flaps Outboard (graphite) Inboard (graphite/fiberglass) Tip fairings (fiberglass) Rudder (graphite) Fixed trailing edge panels graphite /Kevlar + nonwoven Kevlar mat) Elevators (graphite) Fixed trailing edge panels upper (graphite /fiberglass), lower (graphite /Kevlar + non-woven Kevlar mat) Fixed trailing edge panels Graphite/Kevlar + non-woven Kevlar mat

Auxiliary power inlet graphite

Nose landing gear doors (graphite) Wing to body fairings (graphite/Kevlar/Fiberglass and Graphite/Kevlar + nonwoven Kevlar mat

Spoilers (graphite) Wing leading edge lower panel Cowl components Kevlar/fiberglass (graphite) Body main landing gear doors (graphite) Trunnion fairings and wing landing gear doors (graphite/Kevlar) Brakes( structural carbon)

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From http://matse101.mse.uiuc.edu/

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Terminology
Matrix:
softer, more flexible and continuous part that surrounds the other phase. transfer stress to other phases protect phases from environment

Reinforcement (dispersed phase):

stiffer, high strength part (particles or fibers are the most common). enhances matrix properties C fibers: very stiff very strong C matrix: less stiff less strong view onto plane fibers lie in plane
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Composite characteristics
Depends on: - properties of the matrix material. - properties of reinforcement material. - ratio of matrix to reinforcement. - matrix-reinforcement bonding/adhesion. - mode of fabrication.
7 orientation distribution concentration size shape

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Classification of Composites
Matrix-based:
Metal Matrix Composites (MMC) Ceramic Matrix Composites (CMC) Polymer Matrix Composites (PMC)

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COMPOSITE BENEFITS
CMCs: Increased toughness
Force
particle-reinf

PMCs: Increased E/
ceramics

10 3 E(GPa) PMCs 10 2 10

fiber -reinf un-reinf

metal/ metal alloys

Bend d isplacement 10 -4 1) ss (s -1 10 -6 10 -8

.1 G=3E/8 polymers .01 K=E .1 .3 1 3 10 30 Density, [Mg/m 3 ]

6061 Al 6061 Al w/SiC whiskers

Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp. 139-146, 1984. Used with permission.

MMCs:

Increased creep resistance

From Callister resources CD

10 -10 20 30 50 2007, 2008 Moonsub Shim

(MPa) 10 0 200

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Reinforcement-based

dparticle< 100nm dparticle>100nm

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COMPOSITE SURVEY: Particle-I

Particle-reinforced Examples: matrix: -Spheroidite p ferrite ( ) steel
(ductile)

Fiber -reinforced

Structural
particles: cementite (Fe 3 C) (brittle)
Adapted from Fig. 10.10, Callister 6e. (Fig. 10.10 is copyright United States Steel Corporation, 1971.)

60 m

-WC/Co cemented carbide

matrix: cobalt (ductile) Vm : 10-15vol%! matrix: rubber (compliant)

particles: WC (brittle, hard) 600 m particles: C (stiffer) 0.75 m

Adapted from Fig. 16.4, Callister 6e. (Fig. 16.4 is courtesy Carboloy Systems, Department, General Electric Company.) Company )

-Automobile tires
From Callister resources CD

Adapted from Fig. 16.5, Callister 6e. (Fig. 16.5 is courtesy Goodyear Tire and Rubber Company.)

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COMPOSITE SURVEY: Particle-II

Particle-reinforced -- two approaches. approaches
E(GPa) 350 Data: Cu matrix 30 0 w/tungsten 250 particles 20 0 150 0

Fiber -reinforced

Structural

Elastic modulus, Ec, of composites:

upper limit: rule of mixtures E c = VmE m + Vp E p lower limit: V 1 V = m + p Ec Em Ep
20 40 60 80 10 0 vol% tungsten
Adapted from Fig. 16.3, Callister 6e. (Fig. 16.3 is from R.H. Krock, ASTM Proc, Vol. 63, 1963.)

(Cu)

(W)

Application to other properties:

-- Electrical conductivity, e: Replace E by e. -- Thermal conductivity, k: Replace E by k.

From Callister resources CD

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Analogy to resistors in series vs. parallel MSE280

Fiber-reinforced composites

Continuous & aligned 2007, 2008 Moonsub Shim

Discontinuous & aligned

Discontinuous & random

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Fiber-reinforced composites
The Fiber Phase
Smaller diameter fiber is stronger than bulk in most materials ( (especially i ll b brittle i l ones). ) Wh Why? ? Flaws! Whiskers: very thin single crystals that have extremely large aspect ratios. high degree of crystallinity and virtually flaw free exceptionally high strength. usually extremely expensive. some whisker materials: graphite, SiC, silicon nitride, aluminum oxide. Fibers: polycrystalline or amorphous. typically: polymers or ceramics (polymer aramids, glass, carbon, boron, SiC Fine Wires: relatively large diameter, often metal wires. e.g. steel, molybdenum, tungsten 2007, 2008 Moonsub Shim

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Fiber-reinforced composites
The Matrix Phase
can

be metal metal, polymers polymers, or ceramics. ceramics

typically metals and polymer because some ductility is often desired. main functions of the matrix: -Hold fibers together. -Transmit and distribute external stress to the fibers. -Protect fibers from surface damage: abrasions, chemical reactions in CMCs, reinforcements are usually added to improve fracture toughness .
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Fiber-reinforced composites
The Fiber-Matrix Interface
1.

Molecular entanglement (interdiffusion):

Entanglement of molecules at the interface. Especially important in fibers that are precoated with polymers. Molecular conformation/structural and chemical aspects.

2.

Electrostatic attraction

+ + + + + + + - - - - - -

- - - + + + -

+ -

- + + -

Depends on surface charge density. e.g. glass fibers, polymers with chargeable groups.

3.

Covalent bonding
Usually the strongest fiber-matrix fiber matrix interaction. The most important in many composites.
A B A B A B

4.

Mechanical adhesion
Interlocking of 2 rough surfaces e.g. thermosetting resins
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Fiber-reinforced composites
Properties depend on LENGTH and ORIENTATION of the fibers (as well as isolated properties of each of the components)! Critical fiber length

* fd lc = 2 c

* f =
d= c =

Fiber tensile strength Fiber diameter Smaller of: fiber-matrix bond strength matrix shear yield strength.

Continuous when fiber length >> lc Discontinuous when fiber length < 15 lc

Possible failure modes: 1) fiber breaking. 2) matrix breaking. 3) fiber pullout (interface between fiber and matrix fails)
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Fiber-reinforced composites

Short fibers
(x)

Long fibers
(x)

Poorer fiber efficiency

Better fiber efficiency

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Aligned fibers
Continuous when fiber length >> lc Discontinuous when fiber length < 15 lc

Elastic Modulus

Not so detrimental since: 1) Not all fibers fail at the same time 2) Matrix still intact

0o

90o

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min 19 MSE280

COMPOSITE SURVEY: Fiber-I

Fiber-reinforced Particle-reinforced Aligned Continuous fibers Examples:
--Metal: '(Ni3Al)-(Mo)
by eutectic solidification. matrix: (Mo) (ductile)

Structural

--Glass w/SiC fibers

formed by glass slurry Eglass = 76GPa; ESiC = 400GPa.

(a)

fracture surface
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). Used 20 with permission of CRC Press, Boca Raton, FL. MSE280

2 m

fibers: (Ni 3 Al) (brittle)

From W. Funk and E. Blank, Creep deformation of Ni3Al-Mo in-situ composites", Metall. Trans. A Vol. 19(4), pp. 987-998, 1988. Used with permission.

(b)

2007, 2008 Moonsub Shim From Callister resources CD

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Continuous-aligned fibers
Consider a composite with fibers having square rod geometry with stress in the longitudinal

direction
fiber B

b B Matrix L

When l >> lc (typically l > 15 lc), ) we can simplify to: l then Lcomposite = L fiber = Lmatrix B b 2007, 2008 Moonsub Shim

L since , l

composite = fiber = matrix

ISOSTRAIN
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Continuous-aligned fibers
Longitudinal loading
What about elastic modulus? Total force on the composite is simply the sum of forces on matrix and fibers: l

Fcomposite = Fmatrix + F fiber

, we have:

since

F A

or

F = A

c Ac = m Am + f A f
Sub-in for stresses

Recall stress-strain relation:

= E

Ec c Ac = Em m Am + E f f A f
Imposing isostrain condition c

rearrange

Ec =

= f = m ,

Em m Am E f f A f + c Ac c Ac

Ec = E m

Area fractions 2007, 2008 Moonsub Shim Prefer volume fractions.

Af Am + Ef Ac Ac

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Continuous-aligned fibers
Longitudinal loading
Total area = Bb Af = number of fibers x area of each fiber = Then we have: Af Ac = Nb B Also, Nb2 l

Am = Ac A f or Af Am Nb = 1 = 1 Ac Ac B

For volume fractions: Vc = Bbl

V f = Nb 2l
Then: v f =

Vf Vc

Nb 2l Nb A f = = Bbl B Ac

same as area fraction

Similarly,

vm =

Am Ac

Ecl = vm Em + v f E f
Longitudinal elastic modulus 23 (upper bound for Ec) MSE280

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Continuous-aligned fibers
Longitudinal loading
What about the load on the matrix and the fibers? l

Ff Fm
Ff Fm
With

=?

F = A

f Af f v f = m Am m vm

= E
= Ef f vf E m m vm
Isostrain conditions

Ff Fm

Ff Fm

Ef vf E m vm
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Continuous-aligned fibers
Transverse loading
Stress, rather than strain, is the same in this case: B

c = f = m

ISOSTRESS condition

The total elongation will be the sum of elongation of the components:

Lc = L f + Lm

Strain = c =

Lc L f Lm = + Lc Lc Lc

Where Lc = length of the composite along the direction of stress = B

Again, to express in terms of volume fractions:

L f = Nb Lf Nb = vf = Lc B
Rearrange

Lc =

Lf vf

Similarly,

Lc =

Lm vm

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Same as what we derived for volume fraction

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Continuous-aligned fibers
Transverse loading
L L L c = c = f + m Lc Lc Lc L f L f Lm L = + = vf + vm m Lm L f / v f Lm / vm Lf
l B b

c = vm m + v f f
c
Ec = vm

m
Lower bound for Ec (transverse modulus)

From stress-strain relation; =

m
Em

+ vf

f
Ef

Ect =

Em E f vm E f + v f E m
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Applying isostress condition and rearranging gives 2007, 2008 Moonsub Shim

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Continuous-aligned fibers
Many properties follow these upper and lower bound relations for continuous-aligned fiber composities. In general: l B b

cl = cupper = vm m + v f f
ct = clower =
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m f vm f + v f m
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Continuous-aligned fibers: example

1. Calculate the longitudinal and transverse modulus and thermal conductivity for polyester reinforced with 60% volume fraction of glass fiber (E (E-glass). glass). Calculate longitudinal specific stiffness. Calculate the percentage of the load on the fibers for longitudinal loading.
E(GPa) Polyester E-glass 2007, 2008 Moonsub Shim 6.3 72.4 K(W/mK) 0.17 0.97 Specific gravity 1.46 2.58
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2. 3.

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Continuous-aligned fibers: example Mixed Fibers

A two-fiber composite (continuous aligned) i composed is d of f th the f following ll i components. t
E(GPa) Kevlar fiber E-glass fiber Epoxy matrix 131 72.5 2.41 Vol. fraction 30% 20% 50%

Calculate the longitudinal elastic modulus.

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Continuous-aligned fibers l
Tensile strength
Longitudinal:
* ' * cl l = vm m + v f f

Similar to elastic modulus b

This is assuming that the fiber fails prior to the matrix. ' m = Stress in the matrix at failure

* f =

Tensile strength of the reinforcement fiber

Transverse: more complex due to many factors that affect it (e.g. matrix & fiber properties, fiber-matrix bond strength, presence of voids etc)

In general, stronger along longitudinal direction

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Discontinuous & aligned fibers

Discontinuous when fiber length < 15 lc If l > lc
* cd =* f v f 1

lc ' + m vm 2l

Similar to continuous case, except for the length factor.

If l < lc

* cd ' =

= l c ' vf +m vm c d

Smaller of: fiber-matrix bond strength matrix shear yield strength. 31

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Discontinuous & random fibers

Discontinuous, random 2D fibers Example: Carbon-Carbon --process: fiber/pitch, then burn out at up to 2500C. --uses: disk brakes, gas turbine exhaust flaps, nose cones.
(b)

view onto plane

C fibers: very stiff y strong g very C matrix: less stiff less strong fibers lie in plane

Ec = Em Vm + KE f Vf
efficiency factor (depends on vf and Ef/Em): --aligned 1D: K = 1 (anisotropic) --random 2D: K = 3/8 (2D isotropy) --random 3D: K = 1/5 (3D isotropy)

(a)

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From Callister resources CD MSE280

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Polymer matrix composites

Glass fiber-reinforced polymer (GFRP) composites: it fiberglass fib l
Some reasons for using glass as fibers:
Easy to draw fibers from molten state. Strength. Readily available/economic. Chemical inertness (e.g. ) non-corrosive).

Applications: automotive & marine bodies, storage containers, industrial flooring

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Polymer matrix composites

Carbon fiber-reinforced polymer (CFRP) composites:
Some reason for using C-fibers:
Highest specific modulus and specific strength of all reinforcing fiber materials. Retain high modulus and TS at elevated T (chemical oxidation may be a problem). At or near RT, very inert. Can engineer specific mechanical and physical properties properties.

Some applications: fishing rods, golf clubs, bicycles, military and commercial aircraft structural components
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Polymer matrix composites

Aramid (e.g. Kevlar) fiber-reinforced polymer composites:
High strength, high modulus. Much better strength-to-weight strength to weight than metals metals. Stable to relatively high T (high mechanical properties maintained from ~ - 200 to 200oC). Relatively inert chemically (except strong acids). Uses: bullet-proof vests, tires, ropes, missile cases, parts for automotive brake, clutch lining and gaskets

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Carbon-carbon composites
Carbon fiber reinforced carbon matrix p composites.
High modulus & TS (retained to T > 2000oC). Resistant to creep. Large fracture toughness. Small thermal expansion coefficient. High thermal conductivity. Uses: rocket motors, friction material for aircraft and hi h high-performance f automobile t bil b brakes, k components t f for turbine engines Very expensive mainly due to relatively complex processing.
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Carbon nanotube composite

Carbon matrix

Material Aluminum alloys Steel Tungsten Carbon Nanotube

Youngs Modulus 72 GPa 200 GPa 400 GPa >1000 GPa

1m

Nanotube bundles

Ajayan et al.

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Processing of fiber-reinforced composites

Pultrusion

Prepreg production process

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Processing of fiber-reinforced composites

Filament winding

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Design example
F

Requirements

- at F = 890N, deflection < 0.33mm - Circumferential winding with = 15o

A) Which fiber(s), if embedded in epoxy matrix, meet the these criteria? B) Decide D id on th the most t cost-effective t ff ti fiber. fib

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Concepts to remember
Matrix & reinforcement. What composite characteristics depend on. Classification Cl ifi ti : matrix-based ti b d MMC, MMC CMC CMC, PMC; PMC reinforcement-based. Particle reinforced composites: upper and lower bound for E (rule of mixtures). Fiber-reinforced composites Continuous-aligned, discontinuous-aligned & discontinuous-random cases. Critical Cii ll length. h Longitudinal & transverse properties. Isostrain & isostress cases. Structural composites.
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