Chapter 8

Composites
Properties & Applications

8-1
 Introduction

• Every material is composite at one or the other

level.
• A composite material is a material system, a
mixture or combination of two or more micro or
macroconstituents that differ in form and
composition and do not form a solution.
• Properties of composite materials can be superior
to its individual components.
• Examples: Fiber reinforced plastics, concrete,
asphalt, wood etc.

8-2
 Composites

Particle-reinforced Fiber-reinforced Structural

Large- Dispersion- Continuous Discontinuous Laminates Sandwich

particle strengthened (aligned) (short) panels

Aligned Randomly
oriented
 Terminology/Classification

• Composites: woven
-- Multiphase material w/significant fibers
proportions of each phase.
• Matrix (primary phase):
-- The continuous phase
-- Purpose is to: 0.5 mm
- transfer stress to other phases cross
- protect phases from environment section
-- Classification: MMC, CMC, PMC view
metal ceramic polymer
• Dispersed (secondary) phase: 0.5 mm
-- Purpose: enhance matrix properties.
MMC: increase y, TS, creep resist.
CMC: increase Kc
PMC: increase E, y, TS, creep resist.
-- Classification: Particle, fiber, structural
 Particle-reinforced Fiber-reinforced Structural
• Examples:
- Spheroidite matrix: particles: Adapted from Fig.

steel ferrite () cementite 10.19, Callister 7e.

(Fig. 10.19 is
(ductile) (Fe3C) copyright United
States Steel
(brittle)
60 m
Corporation, 1971.)

Adapted from Fig.

- WC/Co matrix: particles: 16.4, Callister 7e.
cemented cobalt WC (Fig. 16.4 is courtesy
Carboloy Systems,
(ductile) (brittle,
carbide V m: hard)
Department, General
Electric Company.)

10-15 vol%! 600 m

Adapted from Fig.
16.5, Callister 7e.
- Automobile matrix: particles: (Fig. 16.5 is courtesy
tires rubber C Goodyear Tire and
(compliant) Rubber Company.)
(stiffer)
0.75 m
Concrete – gravel + sand + cement
- Why sand and gravel? Sand packs into gravel voids

Reinforced concrete - Reinforce with steel rerod or remesh

- increases strength - even if cement matrix is cracked

Pre-stressed concrete - remesh under tension during setting of

concrete. Tension release puts concrete under compressive force
- Concrete much stronger under compression.
- Applied tension must exceed compressive force
Post tensioning – tighten nuts to put under tension
threaded
rod

nut
• Elastic modulus, Ec, of composites:
-- two approaches.
upper limit: “rule of mixtures”
Ec = VmEm + VpEp
E(GPa)
Data: 350
lower limit:
Cu matrix 300
w/tungsten 250 1 Vm Vp
= +
particles 200 Ec Em Ep
150
0 20 40 60 80 100 vol% tungsten
(Cu) (W)

• Application to other properties:

-- Electrical conductivity, e: Replace E in equations with e.
-- Thermal conductivity, k: Replace E in equations with k.
 Particle-reinforced Fiber-reinforced Structural
• Fibers very strong
– Provide significant strength improvement to
material
– Ex: fiber-glass
• Continuous glass filaments in a polymer matrix
• Strength due to fibers
• Polymer simply holds them in place
• Fiber Materials
– Whiskers - Thin single crystals - large length to diameter ratio
• graphite, SiN, SiC
• high crystal perfection – extremely strong, strongest known
• very expensive
– Fibers
• polycrystalline or amorphous
• generally polymers or ceramics
• Ex: Al2O3, Aramid, E-glass, Boron, UHMWPE (Ultra-High
Molecular Weight Polyethylene fiber)
– Wires
• Metal – steel, Mo, W
 Fiber Alignment

aligned aligned random

continuous discontinuous
• Aligned Continuous fibers
• Examples:
-- Metal: '(Ni3Al)-(Mo) -- Ceramic: Glass w/SiC fibers
by eutectic solidification. formed by glass slurry
matrix:  (Mo) (ductile) Eglass = 76 GPa; ESiC = 400 GPa.

(a) fracture
surface

From F.L. Matthews and R.L.

2 m Rawlings, Composite Materials;
Engineering and Science, Reprint
fibers: ’ (Ni3Al) (brittle) (b)
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
with permission of CRC
Press, Boca Raton, FL.
• Discontinuous, random 2D fibers
• Example: Carbon-Carbon C fibers:
-- process: fiber/pitch, then very stiff
burn out at up to 2500ºC. very strong
-- uses: disk brakes, gas (b)
C matrix:
turbine exhaust flaps, nose less stiff
cones. view onto plane less strong
fibers lie
(a) in plane

• Other variations:
-- Discontinuous, random 3D
-- Discontinuous, 1D
 Particle-reinforced Fiber-reinforced Structural
• Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0º/90º
-- benefit: balanced, in-plane stiffness

• Sandwich panels
-- low density, honeycomb core
-- benefit: small weight, large bending stiffness
face sheet
adhesive layer
honeycomb

Adapted from Fig. 16.18,

Callister 7e. (Fig. 16.18 is
from Engineered Materials
Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)
 Polymer Matrix Composite (PMC)

• Glass fiber reinforced plastic composite materials

have high strength-weight ratio, good dimensional
stability, good temperature and corrosion
resistance and low cost.
➢‘E’ Glass : 52-56% SiO2, + 12-16% Al2O3,
16-25% CaO + 8-13% B2O3
❖ Tensile strength = 3.44 GPa, E = 72.3 GPa

➢‘S” Glass : Used for military and aerospace

application.
➢ 65% SiO2 + 25% Al2O3 + 10% MgO
❖ Tensile strength = 4.48 GPa, E = 85.4 GPa
 Fiber Reinforced-Plastic Composite Materials

• Fiberglass-reinforced polyester resins:

➢Higher the wt% of glass, stronger the reinforced
plastic is.
➢Nonparallel alignment of glass fibers reduces
strength.
• Carbon fiber reinforced epoxy resins:
➢ Carbon fiber contributes to rigidity and strength
while epoxy matrix contributes to impact strength.
➢ Polyimides, polyphenylene sulfides are also used.
➢ Exceptional fatigue properties.
➢ Carbon fiber epoxy material is laminated to meet
strength requirements.
 Properties of Fiber Reinforced Plastics

Fiberglass polyester

(Carbon fibers and epoxy)

 Ceramic-Matrix Composites (CMCs)

• Continuous fiber reinforced CMCs:

➢ SiC fibers are woven into mat and SiC is impregnated
into fibrous mat by chemical vapor deposition.
➢ SiC fibers can be encapsulated by a glass ceramic.
➢ Used in heat exchanger tube and thermal protection
system.
• Discontinuous and particulate reinforced CMCs:
➢ Fracture toughness is significantly increased.
➢ Fabricated by common process such as hot isolatic
pressing.
 Portland Cement

• Production: Lime (CaO), Silica (SiO2),

alumina(Al2O3) and iron oxide (Fe2O3) are raw
materials.
• Raw materials are crushed, ground and proportional for
desired composition and blended.
• Mixture is fed into rotary kiln and heated to 1400-16500C
and then cooled and pulverized.
• Chemical Composition:
 Types of Portland Cement

• Types of Portland cement differ by composition.

• Type I: Used when high sulfate attack from soil and water,
and high temperature are absent.
➢ Examples: Sidewalks, buildings, bridges.
• Type II: Used in case of moderate sulfate attack as in case
of drainage.
• Type III: Early strength type for quick use.
• Type IV: Low heat of hydration type and used when rate
and heat generated must be minimized.
• Type V: Used for heavy sulfate attack as in case of
groundwater.
 Hardening of Portland Cement

• Tricalcium silicate and dicalcium silicate constitute 75% of

portland cement.
• Hydration reactions:
2C3S + H2O C3S2.3H2O + 3Ca(OH)2
2C2S + 4H2O C3S2.3H2O + Ca(OH)2

Tricalcium silicate hydrate

• C3S is responsible for early strength.

• Most of compressive strength is
developed in 28 days.
• Strengthening might continue
for years
 Metal Matrix Composites (MMCs)

• Continuous fiber reinforced MMCs: Continuous fibers are

reinforced in metal matrix – used in aerospace, auto
industry and sports equipments.
• Example:- Aluminum alloy – Boron fiber composite
➢ Boron fiber is made by depositing boron vapor on tungsten
substrate.
➢ Boron fibers are hotpressed between aluminum foils.
➢ Tensile strength of Al6061 increases from 310 to 1417GPa and E
increases from 69 to 231 GPa
Tungsten filament

Boron
 Discontinuous fiber and particulate reinforced MMCs

• Particulate reinforced MMCs: Irregular shaped alumina

and silicon carbide particulate are used.
➢ Particulate is mixed into molten aluminum and cast into ingots or
billets.
➢ Al 6061 + 20% SiC Tensile strength increased to 496 MPa
‘E’increased to 103 GPa
• Discontinuous fiber reinforced MMcs: Needle like SiC
whiskers (1-3 micron diameter, 20-200 micron in length)
are mixed with metal powder.
➢ Mixture is consolidated by hot pressing
and then forged or extruded.
➢ Tensile strength of Al 6061 increases to
480 MPa and ‘E’ increases to 115 GPa
 Composite Benefits

• CMCs: Increased toughness • PMCs: Increased E/

Force ceramics
particle-reinf 103
E(GPa) 2 PMCs
10
10 metal/
fiber-reinf metal alloys
1
un-reinf
.1 G=3E/8 polymers
.01 K=E
Bend displacement .1 .3 1 3 10 30
10-4 Density,  [mg/m3]
ss (s-1) 6061 Al
• MMCs: 10-6 Adapted from T.G. Nieh, "Creep rupture of a
Increased silicon-carbide reinforced aluminum
composite", Metall. Trans. A Vol. 15(1), pp.
creep 10-8 6061 Al 139-146, 1984. Used with permission.
resistance w/SiC
whiskers
(MPa)
10 -10
20 30 50 100 200
Questions

Q1) Identify some of the characteristic properties of

composite materials.
Q2) What are the two forms of sandwich structure among
laminar composite structures? Briefly describe each.
Q3) Give some examples of commercial products which are
laminar composite structures.
Q4) What are the three general factors that determine the
properties of a composite material?
Q5) What are some of the weaknesses of ceramics that might
be corrected in fiber-reinforced ceramic matrix composites?
Q6) Name some of the important applications of FRPs.
Samples of “Ceramics” questions

Q1) What is the difference between traditional ceramics

and new ceramics?

Q2) What are the general mechanical properties of ceramic

materials?

Q3) What are some of the principal applications of the

cemented carbides, such as WC-Co?

Q4) What is one of the important applications of titanium

nitride, as mentioned in the text?