Universidad Carlos III de Madrid Materials Science and Engineering course covers composite materials

Universidad
Carlos III de Madrid MATERIALS SCIENCE AND ENGINEERING

www.uc3m.es
TOPIC 10.
10 COMPOSITE MATERIALS (S
(Session
i I)
Introduction
Concept of composite materials
Constituents of composite materials
Classification of composite
p materials
Why polymers are used in Composite Materials?
Reinforcements
Particles
Fibers
Mechanical properties of different reinforcement materials
Laminated Structures
Dpt. Materials Sci. and Eng. and Chemical Eng. UC3M Aerospace Materials I
Topic 10: Composite Materials
What is a composite material?
Mix of two or more constituent materials with significantly different physical or

chemical p
properties
p which remain separate
p and distinct on a macroscopic
p or
microscopic level within the finished structure.
Usually a synergistic effect in one or more properties is observed.
When is a material considered to be a composite?

Microstructural level (< 0,01 cm) to macrostructural (> 0,01 cm)
• Wood • Concrete
• Hypoeutectoid steel
• Austenitic stainless steel
? • Reinforced concrete
• Cement
p
• Cellophane
• Paper
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials I
What is a composite material?
material?- The result from a “clever”
clever combination of two or more different
materials
SYNERGYSM All kinds of Advanced
ANISOTROPY
INTERFACES Composites Composites
SYNERGISM: The overall performance of the material should be better than the separate
components for a particular applications. Properties vary continuously over a range.
ANISOTROPY IN GEOMETRY. Alignement control of fibres allows tailoring mechanical properties.
When composites are extremely anisotropic, with hard interphases (large gradient in
composition and properties) and designed for structural applications: Advanced Composite
Materials.
When a composite
p is made of long
g and extremelyy stiff reinforcement FIBRES aligned
g in specific
p
directions and immersed in a polymer MATRIX: Advanced Polymer Composite Material.
COMPOSITES IN NATURE
Abalone shell:
CaCO3
+ 3% organic material
>3000* stronger than calcite
Bettye L. Smith (UCSB)

SEM
Wood
cellulose-filaments in a matrix of lignin and hemicellulose
growth rings form a layered composite
perpendicular to the growth rings are radially oriented

ribbon-like structures : rays which provide a redial
stiffening and reinforcement
Juniperrus ashei wood
1. Reinforcement / Fibres:
 The reinforcements impart their special mechanical and physical properties to
enhance the matrix properties.
p p
2. Matrices: GOOD BONDING

 Form the shape of the component FIBERS  MATRIX
 Transfers load into and out of the fibres IS REQUIRED
 Separates the fibres to prevent failure of adjacent fibers if one fails
 Protects the fibre from the environment (degradation)
 Keeps fibre orientation
INTERFACE: The planar region that separates two components in any material. Is
regarded as the third phase in the composite because the matrix structure is modified
close to the fiber surface.
surface
Both the fiber and matrix can be a polymer, a metal or a ceramic. The properties of
p
composites are a function of the p properties
p of the constituent p
phases, their relative
amounts, and the geometry of the dispersed phase.
Properties of composite materials for different matrices and the reinforcements

Matrix Reinforcement material Properties
Mechanical strength to high temp
Metal Metal fibers, ceramic, carbon, glass
Electric conduction.  thermal stability
Particles and metallic fibers and Chemical and thermal resistance to
Ceramic
ceramics
i t
temp. 
Mechanical strength and chemical
Glass Glass and ceramic particles
resistance to temp. thermal stability
. chemical and electrical
electrical, and erosion
Organic Carbon, glass and organic fibers
resistance, flexibility
Classification of composite materials
. According to the matrix:

 Metal matrix composites (MMC)
 Ceramic matrix composites (CMC)
 Polymeric matrix composites (PMC)
According to the reinforcement:

 Particles (dispersion strengthened - large particles -nanoparticles)
 Fibers ((discontinuous - short or continuous – aligned-
g woven))
 Structural (laminates and sandwich structures)
Composite: A multi-phase material that exhibits a significant proportion of the properties of the constituent
phases such that a better combination of desirable properties is realized.
Matrix: The continuous phase that surrounds the other constituents and binds them into a composite
material.
Dispersed Phase: The discontinuous, or discrete phase that adds reinforcement to the composite.
Particle: A relatively short globular or spherical dispersed phase.
Fiber: A reinforcement, typically cylindrical, with a diameter smaller than its length
Classification of composite materials
According to the reinforcement:
COMPOSITE MATERIALS
Particle-reinforced Fiber-reinforced Structural
Large- Dispersion
Large Nanoparticles Laminates Sandwich
particle strengthen panels
Continuous Discontinuous Woven

(aligned) (short) fabric
aligned Randomly
oriented
Advantages of advanced polymer composite materials
• Good specific mechanical

performance
• Good fatigue performance
• Low weight
• Custom design
g
• Dimensional stability
• High chemical resistance
• No corrosion problems
• Good fire behavior
• Reduction in number of parts
Composite Design - Demanding Applications

Lightweight and High Strength: Composite products can be designed to be
both lightweight and high strength
strength. Composite designs can be tailored to
meet the specific strength, weight and stiffness requirements of an
application. Many combinations of resin and fiber can used to tailor the
mechanical and physical properties of a structure to meet specific needs
needs.
Corrosion Resistance: Composite products provide long-term resistance to
severe chemical and temperature environments. Composites are the
material off choice for
f outdoor exposure, chemical handling applications, and
severe environment service.
Durability:
y Composite
p structures have an exceedingly
g y long
g life span
p and low
maintenance requirements.
Design Flexibility: Composites have an advantage over other materials
because they can be molded into complex shapes at relatively low cost
cost.
Disadvantages of advanced polymer composite materials
• Costly
y programs
p g for evaluation,,
and certification of structures
• Costly investments for installations
and equipment
• High material cost
• Water entry in sandwich structures
• Low
L impact
i t resistance
i t COMPONENT
• Additional protection for erosion

• Low thermal conductivity. SUB-COMPONENT
Additional protection for lightning

ELEMENTS
• Low recyclability
DETAILS
COUPONS
The application of composites in place of metals requires different approaches to the design and
service of structural components. Labour intensive manufacturing, expensive raw materials,
damage tolerance aspects, and the need for new inspection and repair philosophies that need
to be addressed The factors currently driving new materials applications on commercial aircraft
will place added emphases on
• Design simplification,
• Low-cost processing
• Durability
• Maintainability
•
Comparison of the mechanical performance of composites and light metals
The aerospace sector with the highest interest in lightweight design is of course the space
industry. A kilogram saved can have a value of more than €10000. Therefore, high modulus
carbon fibres are the most important candidates for structural space materials. In addition to
their mechanical performance,
performance the low coefficient of thermal expansion of carbon fibre
reinforced plastics is highly relevant for satellite applications. One use of composites in space
applications is the carbon/carbon technology employed, for example, as the heat shielding
material of re-entry structures or rocket nozzles
.
A sandwich
d i h structure
t t f ultralight
for lt li ht solar
l panels.
l The
Th skin
ki consists
i t off high
hi h modulus
d l carbon
b fibres
fib
produced by a special filament winding technique. The core is extremely light aluminium honeycomb.
T9 -
13
Reinforcements
REINFORCEMENTS
 Particles (dispersion strengthened - large particles -nanoparticles)
 Fibers (discontinuous - short or continuous – aligned- woven)
 Structural (laminates and sandwich structures)
 Factors that have an influence in physical

an mechanical properties: size,
distribution and particle content
concentration size
shape distribution orientation
Reinforcements: Particles
General aspects of particle reinforced composites:
 Advantages of particle reinforced composite materials

Low cost
 High stiffness and strength (inorganic particles)
 Wear resistance
 Simpler manufacturing process
 Mechanical properties depend on the reinforcement, manufacturing and subsequent
treatments
 Most used metallic matrixes are Al, Mg, Ti y Ni
 Polymeric matrixes are reinforced to improve their mechanical strength and abrasion
resistance and electrical conductivity (nanoparticles)
 Dispersed phase: Particles with d=10-250 nm  Dislocation movement is

blocked causing hardening (↑ hardness, ↑ E, ↑ σ).
 Continuous phase: Matrix is bearing the load
Ceramic particles
To select the appropriate reinforcement it should be
taken into account:
 Structural Particle
 High modulus
 Low density
 Particle shape (avoid corners)
 Thermal:
 Expansion coefficient and conductivity Properties of SiC and Al2O3 particles:
System
y Application
pp
Ag-CdO Electrical connectors
Al-Al2O3 Nuclear reactors
Be-BeO p
Nuclear reactor and aerospace
Co-ThO2,Y2O3 Magnetic materials resistant to yield
Ni-20% Cr-ThO2 Turbojet components
Pb-PbO Batteryy grid
g
Pt-ThO2 Wires, electrical components
Examples and applications of dispersion strengthened compounds
C
Composite materials reinforced
f with large particles
 Large particles of a hard and brittle material uniformly scattered in soft and ductile
matrix. Meso-micro scale. The reinforcement bears or helps to bear the load.
 These composites are designed to produce unusual properties and not to improve
strength
 Metals and ceramics  particles are added to improve toughness and mechanical resistance
 Plastics  particles are added as a filling to improve properties (carbon black - soot, elastomers) or
reduce cost (CaCO3, clays, hollow glass spheres…)
Examples and applications
CERMETS (cemented carbides).

carbides)
• Hard ceramic particles such as Tungsten carbide (hard, stiff, and Tm) dispersed in a metallic matrix. Used
as cutting tools
ABRASIVE cutting g and forming
g discs from alumina Al2O3, silicon carbide, SiC cubic boron nitride,
BN. This particles are cemented in vitreous or polymeric matrixes
CAST PARTICLE REINFORCED COMPOSITES
Al casting with SiC particles for applications in the car industry (pistons and connecting rods)
CONCRETE. It is a matrix of cement together with gravel or sand particles. “It is a composite of particles
held together by cement”. Fine aggregate cement (sand), coarse aggregate (gravel) and water
Examples: Particle Reinforced composite
1 m WC–Co
Carbon Black particle cemented carbide
carbide. Light
reinforcement in Styrene- areas are the cobalt matrix;
dark regions, the particles of
Butadine synthetic rubber for
tungsten carbide x100.
car tire application.
application
Reinforcements: Fibers
FIBER-REINFORCED COMPOSITE MATERIALS
Continuous fibers Woven fabric

(aligned) Short or discontinuous fibers
(aligned or randomly scattered)
Longitudinal direction
Transversal
direction
Di ti
Discontinuous d
and Discontinuous and
aligned fibers randomly places fibers
 Types of fibers:
 Glass fibres ((GFRP))
 Carbon fibres (CFRP)
 Aramide (AFRP)
 Other fibers: boron, SiC, Al2O3
 Role of the fibers. Bear most of the load applied to the composite
Glass fibres
 Used to reinforce plastic matrixes
 Composition: Base of SiO2 (50-70%) + Oxides Ca, Al, B, Na, Mg and K
 Properties: non combustible,
combustible good chemical, ↑ ↓)
chemical biological and thermal resistance (Tm↑,↓),
thermal insulator (K↓), electric insulator (↓), low expansion coefficient and low cost
 Strength of glass fibres is determined by: damage during processing, and the adsorption
of water over their surface
• The strength of these fibers is high but not extreme: there are limits in their application
• E glass is the cheapest and has the highest moisture resistance (polymeric matrixes)
Material, % in weight
Type
yp of Secondary
y
Sili
Silica Al i
Alumina C O
CaO M
Magnesium
i B2O3 N 2CO3
Na C F2
CaF
glass Oxides
E (1) 54 14 20,5 0,5 8 1 1 1
A (2) 72 1 8 4 - 14 - 1
ECR 61 11 22 3 - 0,6 - 2,4
S (3) 64 25 - 10 - 0,3 - 0,7
(1) Ca Aluminoborosilicate
(2) Rich in alkali
T
Types and
d composition
iti off different
diff t fiberglass
fib l
(3) Mg Aluminosilicate without B
Glass fibres
Fiberglass properties
Type tensile 
E (GPa)  (K)10
-6
of relative (MPa) ((a 20 ºC y 1 Tm (ºC) For applications that require
glass MHz)
Good electrical properties and dimensional

E 2,58 3450 72,5 5,0 6,3 1065
stability (circuit boards)
A 2 50
2,50 3040 69 0
69,0 86
8,6 69
6,9 996 Chemical resistance
Good electrical properties and chemical
ECR 2,62 3625 72,5 5,0 6,5 1204
resistance
Tensile strength and thermal stability
S 2 48
2,48 4590 86 0
86,0 56
5,6 51
5,1 1454
(aerospace and aeronautic industries)
Sizing: Protective coating applied to glass fibers. Sizing normally contains a film-forming polymer, such
as polyvinyl acetate, and a coupling agent (organosilane, titanate or chromate).
R l off sizings
Role i i
– binds the filaments (d = 10-20 mm) together for ease processing,
– lubricates fibres so they can withstand abrasion,
– imparts anti
anti-static
static properties
– provides some chemical functionalities to the surface to improve interfacial bond strength.
Common polymeric matrixes:

Thermoplastics: Nylon 66,
66 Polycarbonate and Polystyrene
Thermosetting: Epoxy, polyesters, phenolic, silicon
Reinforcements
Glass fibres
There are three typical
configurations for fiberglass
reinforced composite materials:
a) Continuous fibers
b) Discontinuous Glass fabric
c) Woven fiber (dry or prepeg)
Glass reinforcements used for

fiberglass are supplied in different
physical forms, microspheres,
chopped or woven Glass fibers
Composite material fiberglass

reinforced polymeric matrix
(image of the fracture surface)
Carbon fibres
 Advanced composites for aerospace and aeronautic fibers.

 Very good thermal and physical properties (High electrical and thermal conductivity).
 Carbon
C b fib
fibers i composites
in it with
ith plastic
l ti resins
i (i
(i.e.: epoxy)) good
d combination
bi ti off high
hi h
mechanical strength, stiffness and low weight aerospace applications
 Low cost: sport equipment manufacturing, industrial and commercial products (70’s  220
80’ss  9$/kg)
$/kg and 80
Evolution of the applications of carbon fiber during the period 2001-2010 source: M. Kamiura. Toray Carbon
Fiber Composites Materials Businesses. oray IR Seminal-No.7. June 6, 2005)
C b fibres:
Carbon fib IUPAC classification
l ifi ti (according
( di tot mechanical
h i l properties)
ti )
Ultra high elastic modulus type (UHM) :

Tensile elastic modulus: 600 GPa or higher;
Tensile strength: 2500 MPa or higher
High elastic modulus type (HM): Tensile
elastic modulus: 350
350-600
600 GPa; Tensile
strength: 2500 MPa or higher
Intermediate elastic modulus type (IM):
T il elastic
Tensile l ti modulus:
d l 280
280-350
350 GPa
GP ; Tensile
T il
strength: 3,500 MPa or higher
Standard elastic modulus type (HT): Tensile
elastic
l i modulus:
d l 200
200-280
280 GPa
GP ; Tensile
T il
strength: approximately 2500 MPa or higher
Low elastic modulus type (LM): Tensile
elastic modulus: 200 GPa or lower ;
Tensile strength: 3500 MPa or lower
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M (www.carbonfiber.gr.jp). Aerospace Materials I
Carbon fibres: classification accoding to heat treatment temperature
• Type I (or HTT): High degree of orientation (high modulus), High

temperature heat treatment (> 2000ºC)
• Type II (or ITT): less degree of orientation but high strength,
Intermediate temperature (≈ 1500ºC)
• Type III (LTT): random orientation (low strength and modulus). Low
temperature (< 1000ºC
• nanotubes:
promissing reinforcements
Carbon fibres
 Manufactured from organic precursors:
Polyacrylonitrile (PAN –based fibers) (E and tensile strength)
Pitch (Pitch-based fibers) (ioll/coal precursor): Isotropic (E) or anisotropic (mesophase)
(E and tensile strength)
1. PRODUCTION OF ACRYLIC ((PAN)) OR PITCH FIBER (SPINNING)

( )
2. STABILIZATION OR OXIDATION: Stretching (200-300ºC): fibrillar network. Pass the fiber bobbin
or thread through an oxidizing furnace in air
3. CARBONIZATION: The fibers are heat treated at 1000-1500ºC in inert atmosphere ( Removal
O H N) and under longitudinal tension
O,H,N)
4. GRAPHITIZATION: heat treated at T>1800ºC in inert atmosphere . Degree of orientation
increased: ↑E and strength
Type II and Type I

Type III
http://www.carbonfiber.gr.jp/english/tanso/03.html
Carbon Fiber Products
Unidirectional
U idi ti l
tape
Bundles or tows Coil
Individual 1K (1000 filaments)
filaments 3K (3000 filaments)
(5-20 μm) 6K (6000 filaments)
12K (12000 filaments)
24K (24000 filaments)
K cost
Fabric
Carbon Fiber Products and Usage
Types Specifications Major Usage
Fillament A yarn constituted of numerous number of fibers: twisted, Resin reinforcement material for CFRP, CFRTP or C/C
untwisted, twisted-and-untwisted composites, having such usage as Aircraft/Aerospace
equipment sporting goods and industrial equipment parts
equipment,
Tow An untwisted bundle of yarn constituted of extremely Resin reinforcement material for CFRP, CFRTP or C/C
numerous number of fibers composites, having such usage as Aircraft/Aerospace
equipment, sporting goods and industrial equipment parts
Staple Yarn A yarn made of spinning of staples Heat Insulator, Anti-friction material, C/C composite parts
W
Woven ffabric
bi A woven sheet
h t made d off filament
fil t or staple
t l yarn R i reinforcement
Resin i f t material
t i l ffor CFRP,
CFRP CFRTP or C/C
composites, having such usage as Aircraft/Aerospace
equipment, sporting goods and industrial equipment parts
Braid A braided yarn made of filament or tow Resin reinforcement material particularly suitable for
reinforcement of tubular products
C
Chopped f
fiber A chopped fiber
f made off sized or non-sized fiber
f C
Compounded into plastics/resins
/ or portland cement to improve
mechanical performances, abrasion characteristic, electric
conductivity and heat resistance
Milled Powder made by milling fiber in a ball-mill etc. Compounded into plastics/resins or rubber to improve
mechanical performances, abrasion characteristic, electric
conductivity
d ti it and dhheatt resistance
i t
Felt.Mat A felt or mat made by layering up of staple by carding etc. Heat insulator, base material for molded heat insulator,
then needle-punched or strengthened by organic binders protective layer for heat resistance and base material for
corrosion-resisting filter
Paper A paper made from staple by dry or wet paper-making Anti-electrostatics sheets, electrodes, speaker-cone and heating
plate
Prepreg An intermediate material in a form of half-hardened Aircraft/Aerospace equipment, sporting goods and industrial
sheets made of Carbon Fibers impregnated with thermo- equipment parts needing lightness in weight and high
setting resin, qualities of which being stable and performances
sustained long enough and therefore easily applicable for
automatic
t ti sheet-layering
h tl i
Compounds A material for injection moulding etc. made of mixture of Housing etc. of OA equipment taking advantages of electric
thermo-plastics or thermo-setting resins added by various conductivity, rigidity and lightness in weight
additives and chopped fiber and then being compounded
Fillament Woven fabric Braid
Tow Staple Yarn
Chopped fiber Milled Felt.Mat Prepreg Compound
Filament Number of
Type Modulus Mean elastic
Symbol Filaments Modulus (GPa)
3K 3000
6K 6000
Standard 230
12K 12000
24K 24000
6K 6000
Convencional tows
intemediate 12K 12000 300
24K 24000
6K 6000
High 12K 12000 350

24K 24000
45K 45000
Large tows standard 48K 48000 230

80K 80000
Fabrications methods and applications for the different types of carbon fiber products
Fillament
Woven fabric Prepreg Chopped fiber
Types
Filament Manual Automatic Compound

Frabrication winding RTM Autoclave processes molding
method Pultrusion
Applications
Pressure Car bodies, Aircrafts
Vessels ships Aircrafts Sports Computers
Aircrafts equpment
Aramid fibres
 Kevlar polyamide (poly(paraphenylene terephthalamide ))
 The aromatic ring provides thermal stability
 E  due to its configuration: rigid molecules are arrayed in ordered

domains during extrusion they are oriented in the direction of the
flflow
 Thermal and electrical insulator, ↓, high impact strength and ↓E
(compared to carbon)
Types of Kevlar fibers (commercially introduced in 1972 by Du Pont):

Kevlar 49  most used structural composite due to its E
Kevlar 29  high toughness applications (i.e.: bulletproof jacket) 100%Aramid fibre prepreg
K l 149  value
Kevlar l off E  theoretical
th ti l
Properties of the three types of Kevlar

M t i l
Material  (g/cm
( / 3) Dwire (m)
( ) tensile(GPa)
(GP ) E (GPa)
(GP )  (%)
Kevlar 29 1,44 12 3,6 83 4,0
Kevlar 49 1,44 12 3,6-4,1 131 2,8 Aramid fibre woven
K l 149
Kevlar 1 47
1,47 12 34
3,4 186 20
2,0 farbic
Boron fibres
Manufactured through a vapor deposition of B over a core of W

 Properties: very high strength and stiffness
Applications: in Al and Ti matrixes First fibers used as reinforcement
 Limitation: Veryy expensive
p
Orientated Polyethylene fibers
• Obtained by gel spinning

• Elastic modulus is controlled by orientation degree
• Strength controlled by molecular weight
Other ceramic fibres
Mainly quartz (Al2O3, Si3N4,SiC…)

Properties
Properties:: Can resist high T (T>1300
(T>1300 ºC) and thermal shocks
Applications
Applications:: Thermal insulator
insulator.. Not structural applications
applications..
Limitation
Limitation:: veryy expensive
p (5 times the pprice of carbon fiber))
4.2.5. Other ceramic fibres

Carbon Coated
SiC Fibres
SiC fibre-reinforced
Titanium Aluminide (MMC)
Ti3Al
M i
Matrix
Reinforcements
Types of fiber fabric:
BID (bi-directional): cloth has half of the fibers woven parallel to the selvage edge of the cloth
and the other half at right
g angles
g to the selvage,
g g givingg the cloth the same strength
g in both
directions
UND (uni-directional): cloth has 95% of the glass fibers woven parallel to the selvage, giving
exceptional strength in that direction and very little at right angles to it
weft warp
Plain weave 5HS 8HS

2x2 twill
Reinforcements
CARBON, GLASS, ARAMID, and other multi-filament fibers are produced in various fabric forms for
processing into high-perfomance PMCs using pre-preg, resing film or liquid resin injection techniques
woven
fibers
Plain weave
8 HS (harness satin) 0.5 mm
cross
section
view 0.5 mm
4 HS (harness satin) 2x2 twill From D. Hull and T.W. Clyne, An Introduction to
Composite Materials, 2nd ed., Cambridge
University Press, New York, 1996, Fig. 3.6, p. 47.
Reinforcements
Non Crimp p Fabrics (NCFs)

( ) : stitch-bonded materials with zero
elongation made of unbent fiber systems,
Reinforcements
Typical cost of woven fabric
Reinforcements
Mechanical properties common reinforcement materials
Mechanical properties of the different fibers
Reinforcements
Mechanical properties common epoxy PMC materials reinforced with
carbon, aramid and glass fibers
Reinforcements
Mechanical properties common reinforcement materials
Reinforcements
• Comparison of mechanical properties in terms of specific properties.
: quasi‐isotropic
l: bulk
: unidirectional
S
Specific
ifi tensile
t il strength
t th and
d tensile
t il modulus
d l for
f different
diff t fibers
fib in
i an epoxy matrix
ti
Laminated Composites
Formed by composite materials and homogeneous materials

Properties depend on the geometry of the structural elements
Types  laminated composites

 sandwich structures
LAMINATED COMPOSITES
Piling of layers or lamina of unidirectional composite material
Laminar composite
p example:
p continuous and alignedg fiber reinforced p
plastics
with matrixes such as epoxy, polyester, PE, PA, PET…
In order to get different mechanical properties  layers of materials with

different properties are piled, or a different way of piling layers on top of each
other.
LAMINATED COMPOSITES
Orientation of fibers with respect to the lamina:

 Usual fiber orientations: 0, 90, +/-45. By combining these orientations, the desired strength
and stiffness is achieved. Plane isotropy can be achieved.
 Fiber layers arranged in a way so that strength is maximized and weight is minimized.
minimized
 Laminated composites
p must always
y
be symmetric with respect to their
middle plane, and the must also be
balanced to avoid anomalous
distortions in the structure
str ct re
 The strength and stiffness varies

greatly
g y with the orientation.
 A piling of woven materials without

any bonding does not have any
structural use
use. Therefore a matrix is
Piled lamina. The needed.
orientation of the
direction changes in
each of the layers
la ers
 Exclusivelyy unidirectional composites
p
are never used.
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M Aerospace Materials50
I
SANDWICH COMPOSITES
2 external strong layers (face sheets) attached to a layer of less dense material
(core) with low stiffness and low strength
 Role of the face sheets they withstand most of the plane loads and transversal bending
stresses
 Face sheet material Al alloys, fiber-reinforced plastics, Ti, steel and plywood.
 Core material separates both face sheets and resists deformations perpendicular to the
face plane. Provide resistance to shear stress along the planes perpendicular to the face
sheets
Manufacture of a sandwich panel with a

Core materials may have different honeycomb core
and have different structures: polymer
foams, synthetic rubber, inorganic cement
and balsa wood
Typical core with honeycomb

structure thin layers arranged in
hexagonal
g cells.
Applications  ceilings, floors and walls in

buildings, in the aerospace industry (wing
Dpt. Materials Sci. and Eng. and Chem. Eng. UC3M coating, fuselage) Aerospace Materials51
I
FIBER-METAL LAMINATES
GLARE "GLAss-REinforced" Fibre Metal Laminate (FML),
GLARE is a "glass-reinforced" Fibre Metal Laminate (FML),

composed of several very thin sheets of metal (usually aluminum)
intercalated with layers of "prepreg“ fiberglass, all linked together
with
i h an epoxy matrix.
i Sh
Sheets off unidirectional
idi i l prepregs may be
b
aligned in different directions, looking for a suitable mechanical
behavior to stress conditions provided.
FIBER-METAL LAMINATES
GLARE
Although GLARE is a composite material, and manufacturing properties are comparable to
laminate aluminum alloy products, especially in the regard to aspects related to the design,
manufacture,
f t inspection
i ti or maintenance.
i t The
Th GLARE components t manufactured
f t d are built
b ilt and
d
repaired using mainly techniques typical of metallic materials.
The main advantages over conventional aluminum alloys are:
• improved damage tolerance (especially to impact and fatigue)
• better corrosion resistance
• better fire resistance
• lower density.
Airbus A380

Universidad Carlos III de Madrid Materials Science and Engineering course covers composite materials

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Universidad Carlos III de Madrid Materials Science and Engineering course covers composite materials

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Universidad

Carlos III de Madrid MATERIALS SCIENCE AND ENGINEERING

Mix of two or more constituent materials with significantly different physical or

When is a material considered to be a composite?

ANISOTROPY IN GEOMETRY. Alignement control of fibres allows tailoring mechanical properties.

Bettye L. Smith (UCSB)

growth rings form a layered composite

perpendicular to the growth rings are radially oriented

2. Matrices: GOOD BONDING

Properties of composite materials for different matrices and the reinforcements

. According to the matrix:

According to the reinforcement:

Particle-reinforced Fiber-reinforced Structural

Continuous Discontinuous Woven

Advantages of advanced polymer composite materials

• Good specific mechanical

Composite Design - Demanding Applications

Disadvantages of advanced polymer composite materials

• Additional protection for erosion

Additional protection for lightning

Comparison of the mechanical performance of composites and light metals

 Factors that have an influence in physical

shape distribution orientation

 Advantages of particle reinforced composite materials

 Dispersed phase: Particles with d=10-250 nm  Dislocation movement is

Examples and applications

CERMETS (cemented carbides).

Continuous fibers Woven fabric

Good electrical properties and dimensional

Common polymeric matrixes:

Glass reinforcements used for

Composite material fiberglass

 Advanced composites for aerospace and aeronautic fibers.

Ultra high elastic modulus type (UHM) :

Carbon fibres: classification accoding to heat treatment temperature

• Type I (or HTT): High degree of orientation (high modulus), High

1. PRODUCTION OF ACRYLIC ((PAN)) OR PITCH FIBER (SPINNING)

Type II and Type I

Chopped fiber Milled Felt.Mat Prepreg Compound

High 12K 12000 350

Large tows standard 48K 48000 230

Filament Manual Automatic Compound

 E  due to its configuration: rigid molecules are arrayed in ordered

Types of Kevlar fibers (commercially introduced in 1972 by Du Pont):

Properties of the three types of Kevlar

Manufactured through a vapor deposition of B over a core of W

Orientated Polyethylene fibers

• Obtained by gel spinning

Other ceramic fibres

Mainly quartz (Al2O3, Si3N4,SiC…)

4.2.5. Other ceramic fibres

Plain weave 5HS 8HS

Non Crimp p Fabrics (NCFs)

Mechanical properties of the different fibers

• Comparison of mechanical properties in terms of specific properties.

Formed by composite materials and homogeneous materials

Types  laminated composites

Piling of layers or lamina of unidirectional composite material

In order to get different mechanical properties  layers of materials with

Orientation of fibers with respect to the lamina:

 The strength and stiffness varies

 A piling of woven materials without