Lecture 12, 2015.

Design of Composites / Hybrid Materials, or

Filling Holes in Material Property Space (2/2)

Textbook Chapter 12, Tutorial 6

Papers:
Microtruss

core 1

Microtruss

core 2

Foam

Topology

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Hybrid Materials: four families of configurations

Composite
Sandwich

Lattice

Segment

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Review: Fibre and particulate composites: the math

Rule of
mixtures

Reuss
bound

Voigts
bound

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Possible Mg-matrix fibre reinforced composites

E1/2/
(criterion of excellence
for beams)

Voigt's
bound

Reuss'
bound

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Hybrid Materials: four families of configurations

Composite

Sandwich

Lattice

Segment

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Hybrid Materials of Type 2: Sandwich Panels

Strong/stiff faces
carry most of the load
(flexural stiffness)

Core is
lightweight,

Resists shear

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A Sandwich Panel as a Monolithic Material: the Maths

Rule of mixtures for density
Fibre composites
f = 2t/d Sandwich panels

Rule of mixtures for stiffness face

Fibre composites (tension)
Sandwich panels (bending)

E face

equivalent
flexural
modulus (P.320)
c = t d, Ec ~0

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The efficiency of Sandwich Structures: S/W Panels vs Monolithic Materials

E1/3/
face

Optimum
at f = 0.04

core

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Hybrid Materials: four families of configurations

Composite

Sandwich

Lattice

Segment

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Hybrid Materials of Type 3 and 4:

Cells, Foams and Lattices & Segmented structures

There are two main types of Lattices:

Bending dominated and Stretch dominated

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Bending dominated structures

Cable

Leaf
spring

We use Shaping to give the sections a LOWER flexural stiffness

per kg than the solid sections from which they are made.
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Bending dominated structures: Foams

Prove this
F

Prove:
Proportionality
constant of
order 1

F
F

Very flexible structure = low effective E*

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Compressive deformation behaviour of foams

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Collapse of foams
metallic foam
(plastic hinges)

elastomeric
foam
(elastic
buckling)

ceramic foam
(hinges crack)

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Stretch dominated structures

flexible

rigid

over-constrained

b for beams
j for joints

2D lattice

3D lattice
bending-dominated
(mechanism)

stretch-dominated structures

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Stretch dominated structures:

A micro-truss structure

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Micro-truss core designs for panels and towers

Periodic cellular material cores are based on a regularly repeating

geometric unit, or cell, like a cube (square honeycomb) or pyramid.
This technology allows for consistently spaced open-cells, which
facilitate the addition of materials like magnets, cables, or ceramics,
for example and therefore increase functionality. The open cells also
permit fluid flow that can achieve more efficient thermal management.

Communications Tower
Guangzhou City
http://www.cellularmaterials.com/coredesigns.asp

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http://etd.gatech.edu/theses/available/etd-11222005-162952/unrestricted/wang_hongqing_v_200512_phd.pdf

Bone = Foam (bending dominated) or

= Micro-truss (stretch dominated)?
A foam in a panels core behaves like a micro-truss structure:
shear stretches the diagonals of the cell walls, whereas the
panels faces are under stretching stresses. (See the bubble
charts in slides 28-29 later on)
http://www.srl.gatech.edu/publications/2005/DETC2005-85366.pdf

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(Zhang et al, 2015) Distribution of local strains. Stretched in tension by

Mg-La (30% solid) (a) ~0.4% and (b) ~0.6% strain and (c) ~0.8% strain.

Mg-Nd (7.5% solid) (a) 0.4%

(b) 0.8%

22

Stretch-dominated vs bending-dominated behaviour

Mg-La

Mg-Nd

Mg-La
Stretch-dominated
30% vol. fraction of solid
Mg-Nd Bending-dominated
7.7% vol. fraction of solid
23

.
Stretch dominated

Isotropic
foams
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(2/2)

Bending
dominated
Transition between
S-D to B-D at24/35
20%

http://www.asminternational.org/news/industry/-/journal_content/56/10180/25845663/NEWS

25

Stretch Dominated vs. Bending Dominated hybrids

Micro-truss hybrids: ultraligth, high flexural stiffness

Foams: ultralight, very flexible

1/3 of the bars are

loaded in tension

Micro-truss (Stretch dominated)

linear relationships Design assumes
flexural macroscopic loading

Foams: power law relationships

(involve the second moment I)
Design assumes compressive loading

Panels with foamed cores: linear relationship as well

E(flex)/Ef ~ (/s) (panel stretch dominated structure)

Linear at
low f=t/d

(prove it!)
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sound
polymer

Open Cell Foam

properties

Textbook pp. 333-334

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Stretch
dominated
lattice

Stretch dominated:
doubles the stiffness

Open Cell Foam

properties
Stretch dominated:
trebles the strength
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Bending-dominated vs Stretch dominated

Foams: form a line of
Slope 2 (E = (/s)2Es)

Micro-truss: line of
Slope 1 (E = (/s)Es)

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E (tension or
flexural)

Micro-truss structures
fill up another hole in
property space
Micro-truss
Slope 1

Sandwich panels also

belong in here (slope 1)

Foams

Eflex /Eface~ /o

Ef =(/s)2 Es

Slope 2

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http://www.cellularmaterials.com/advantages.asp
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Hybrid Materials: four families of configurations

Composite

Sandwich

Lattice

Segment

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Unbonded structures
that carry load
carry
in-plane
loads

bricks take
compression
but not
tension or
shear

require a
continuous
clamping
edge

carry out-ofplane forces

and bending

Examples of topological interlocking

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Scale effects on the

strength of microtruss structures
Ashby & Brechet, 2003
Weibull
modulus m

metals

ceramics

Gain in
strength

*s / *t = 1

Finer
this way
Loss of
strength

The strength of low Weibull

modulus (ceramics) microtruss structures increases
with segmentation
The strength of high Weibull modulus
(metals) micro-truss structures does not
increase with segmentation

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The strength of ceramic foams of different cell sizes

Compressive
strength

For given density, foams

with fine cells are some 5
times stronger than
foams with coarse cells

5x

density
Colombo and Bernardo, Composites Sci. Tech., 2003, 63, 2353-2359.

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Hybrids: The main points

Combining properties may help filling holes and
empty areas in material property-space maps.

Appropriate Hybrid materials can be created by

combining material properties and shape, the latter at
either micro or macro scale.

Properties of hybrid materials can be easily

bracketed by simple mathematical relationships
which allow straight forward description of behavior .

These functional relationships allow exploring new

possibilities.

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The End
Lecture 12 (Hybrids, 2/2)
Tutorial 6 due on Sat Oct. 31st
at midnight.

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See Paper Foam topology in BB

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Example of a segmented structure filling a hole in the Material Property Space

Pareto Plot
Trade-off
surface
1/TS

need strong electrically

conductive material for power line
Best point
empty

A + B + conf + scale
Cu => min elect. resist.
Fe => max TS
interleaving fine strands
Resistivity

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Example of a segmented structure filling a hole in the Material Property Space

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Natural materials

Natural fibre composites: Comprehensive Ashby-type materials selection charts

Darshil U. Shah
Oxford Silk Group, Department of Zoology, University of Oxford, Oxford OX1 3PS, UK

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high-strength foam concrete

Microstructure of high-strength foam concrete

A. Just, B. Middendorf
MATERIALSCHARACTERIZATION60(2009)741748

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