MSE 4118

COMPOSITE MATERIALS

Assoc.Prof. Le Thai Hung

Hanoi University of Science and Technology

Undergraduate advanced program +

Materials Science and Engineering
 To describe synthesis, processing and properties of fibers
for composite reinforcements.
To examine bonding and properties of composite interfaces.
To provide guidelines for selection of the matrix materials.
To describe key processing techniques for producing metal-,
ceramic-, and polymer-matrix composites.
To demonstrate the relationship among synthesis,
processing, and properties in composite materials.
To analyze the mechanics of the composite materials.
To provide theoretical treatment of the composite properties.
• What are the classes and types of composites ?

• Why are composites used instead of traditional materials ?

• How do we estimate composite stiffness & strength ?

• What are some typical applications ?

Traditional materials; natural materials and

artificial materials.
Why Composites are Important?

◼ Composites can be very strong and stiff, yet very

light in weight, so ratios of strength-to-weight and
stiffness-to-weight are several times greater than
steel or aluminum
◼ Fatigue properties are generally better than for
common engineering metals
◼ Toughness is often greater too
◼ Composites can be designed that do not corrode
like steel
◼ Possible to achieve combinations of properties not
attainable with metals, ceramics, or polymers alone
1. Introduction (2 hours) 5. Metal matrix composites (6)
▪ Metal matrix
▪ Definitions and classification
▪ Fiber composites
▪ The benefits of composites ▪ Processing Techniques
2. Reinforcements & Matrix (6 hours) 6. Ceramic matrix composites (6)
▪ Fibers ▪ Ceramic Matrix
▪ Comparison of fibers ▪ Alumina & glass matrix
composites
3. Composite Interfaces (6 hours)
▪ Processing techniques
▪ Bonding mechanisms
▪ Bond strength
7. Composite properties (6)
▪ Elastic properties
▪ Interfacial Toughness ▪ Composite strengths
4. Polymer matrix composites (6hours)
▪ Polymer matrix
▪ Carbon & Glass fiber composites

▪ Processing techniques
A composite is a structural material that consists of two or more different materials
in a macroscopic level that are combined and are not soluble in each other.

+ =

Matrix Reinforcement Composites

◼ Metal Matrix Composites (MMCs)

 Include mixtures of ceramics and metals, such as cemented carbides and other
cermets, as well as aluminum or magnesium reinforced by strong, high stiffness
fibers.

◼ Polymer Matrix Composites (PMCs)

 Thermosetting resins are the most widely used polymers in PMCs. Epoxy and
polyester are commonly mixed with fiber reinforcement.

◼ Ceramic Matrix Composites (CMCs)

 Least common composite matrix. Aluminum oxide and silicon carbide are materials
that can be imbedded with fibers for improved properties, especially in high
temperature applications.

◼ Carbon – Carbon Composites (CCCs)

 Carbon - carbon composites is a composite material consisting of carbon fiber
reinforcement in a matrix of graphite.
Reinforcements
Reinforcements
Matrix
 Composite
Composite
Composite
Steel
Al
Steel
Composite

Steel Steel

Composite
Steel
Al
Al Al Al

Thermal Fatigue
Weight Stiffness Strength
expansion resistance

Comparison between conventional monolithic materials and composite materials

Example Products Air Transportation
Nautical Transportation
Composite materials have fully established themselves as workable engineering materials
and are more relatively commonplace around the world, particularly for structural purpose.
Ground Transportation

Space
Programs
 Civil

Sporting Goods
 Bathroom Furniture

Tanks and Pressure Vessels

Advantages and disadvantages of composites
Limitations of Composite

◼ Properties of many important composites are

anisotropic - the properties differ depending on the
direction in which they are measured – this may be
an advantage or a disadvantage
◼ Many of the polymer-based composites are subject
to attack by chemicals or solvents, just as the
polymers themselves are susceptible to attack
◼ Composite materials are generally expensive
◼ Manufacturing methods for shaping composite
materials are often slow and costly
 Reinforcements for
composites

Le Thai Hung

Department Materials Mechanics and Metal-rolling

School of Materials Science and Engineering
Hanoi University of Science and Technology
 Outline

⚫ Reinforcement materials
⚫ Roles of reinforcement
⚫ Types of reinforcement
• Synthesis and processing
• Properties (advantages and disadvantages)
• Applications
⚫ Comparison of reinforcements
⚫ Reinforcement Selection
⚫ Cost

2
Reinforcement materials

3
Roles of reinforcement
⚫ Function is to reinforce the primary phase
⚫ Imbedded phase is most commonly one of the
following shapes:
• Fibers
• Particles
• Flakes
⚫ In addition, the secondary phase can take the
form of an infiltrated phase in a skeletal or
porous matrix
• Example: a powder metallurgy part infiltrated with
polymer

4
Types of reinforcement

⚫ Inorganics ⚫ Organics
• Glass • Aramid (Kevlar)
• Carbon • Natural fibers
• Sic
• Alumina
• Boron

5
Types of reinforcement

⚫ Glass fiber
• 1938, Russell Games Slayter
⚫ Carbon fibers
• 1958: Union Carbide by Dr. Roger Bacon
⚫ Kevlar
• 1965, Stephanie Kwolek (developed the first liquid
crystal polymer)

6
 Types of reinforcement

a) b) c) d)

- Short chopped fibers - long continuous bundles - near spherical - metallic

- random or oriented - l/d > 10 - not usually for strength - clay
- unidirectional - increase toughness - electrical/heating applications
- multidirectional - fire retardation
- woven or braided

a) Random fiber (short fiber); b) Continuous fiber (long fiber);

c) Particles; d) Flat flakes.

7
Glass fibers

⚫ Among the most versatile industrial

materials known today.
⚫ Made by fusing silica (SiO2) with minerals,
which contain oxides to form a given
composition.
⚫ Bulk properties
• Relatively lightweight
• Moderate strength and compressive strength
• Tolerant of damage and cyclical loading
• Low cost

8
 Glass fibers - Synthesis Processing

Raw materials

Furnace

Bushing

Sizing

Winding

9
Glass fibers - Synthesis Processing

10
Glass fibers - Properties

Letter Designation Property or Characteristic

E, electrical Low electrical conductivity with
low alkali content
S, strength High strength with 33% higher
tensile strength than E-glass
C, chemical High chemical durability
M, modulus High stiffness
A, alkali High alkali or soda lime glass
with good chemical resistance
D, dielectric Low dielectric constant with
superior electrical properties

11
Glass fibers - Properties

12
Glass fibers - Properties

13
Glass fibers - Properties

14
Glass fibers - Products

15
Glass fibers - Applications

⚫ Continuous roving
• Spray up fabrication process
• Bath tubs, shower stalls and many marine application
• Sheet molding compounds
• Fiber reinforced plastic (FRP) automotive body
panels
• Filament winding and pultrusion
• Pipes, tanks, leaf springs

16
 Carbon fibers

⚫ Among the most versatile industrial

materials known today.
⚫ Carbon Fiber made commonly by
Polyacrylonitrile (PAN).
⚫ Properties
• High strengh/weight ratio
• Electric conduction
• Heat resistance
• Low thermal expansion
• High cost

17
 Carbon fibers - Synthesis Processing

Raw materials

Oxidation

Carbonization

Surface treatment

Sizing

18
Carbon fibers - Synthesis Processing

19
Carbon fibers - Properties
1 MPa = 145psi

⚫ High strength to weight ratio

⚫ 10x stronger than steel, yet 5x lighter
⚫ Offer an ultimate tensile strength (35,000psi)
⚫ Very stiff
⚫ Low CTE and mold shrinkage
⚫ Improved resistance to creep and wear (even
with minimal amounts in composite)
⚫ Chemically inert

20
Carbon fibers - Properties

21
Carbon fibers - Products

22
Carbon Fibers - Applications

• Filament
• Aircraft/Aerospace equipment, sporting goods and industrial equipment
parts
• Chopped/Milled Fiber
• Compounded into plastics/resins or portland cement
• Paper
• Anti-electrostatics sheets, electrodes, speaker-cone and heating plate

23
Carbon Fibers - Applications

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 Kevlar

⚫ DuPont’s name for poly-

paraphenylene terephthalamide
⚫ Five times stronger than steel by
weight
⚫ Heat resistant up to 400°C
⚫ Chemically resistant
⚫ Flame resistant, self-extinguishing

25
 Kevlar - Synthesis Processing

⚫ Poly(p-phenylene terephthalamide)

26
Kevlar – Synthesis Processing

⚫ Kevlar is a lyotropic liquid crystal ??????????

⚫ Polymers are dissolved in H2SO4
⚫ Dissolved polymers spun through small die
holes

27
 Kevlar - Properties

⚫ High Tensile Strength ⚫ Low Elongation to Break

at Low Weight ⚫ Low Electrical
⚫ High Modulus Conductivity
(Structural Rigidity) ⚫ Low Thermal Shrinkage
⚫ High Chemical ⚫ Excellent Dimensional
Resistance Stability
⚫ High Toughness ⚫ Flame Resistant
(Work-To-Break) -Disadvantages
-Low compressive strength
⚫ High Cut Resistance -High moisture absorption
-UV light causes discoloration and loss
of mechanical properties

28
Kevlar - Properties

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KEVLAR

⚫ Today, there are three grades of Kevlar available: Kevlar 29,

Kevlar 49, and Kevlar 149. The table below shows the
differences in material properties among the different grades. If
you purchase Kevlar cloth, it is most likely Kevlar 49.

30
 Kevlar - Applications

⚫ Bullet proof vests

(most common)
⚫ Fire resistant textiles
⚫ Asbestos
replacement
⚫ Automotive
⚫ Airlines
⚫ Extreme sports
equipment
31
Some other

32
Some other

33
Some other
Comparison of reinforcement

- Specific tensile strength and modulus

- Thermal stability
- Strain to failure

35
Comparison of reinforcement

36
Comparison of reinforcement

37
Comparison of reinforcement

38
Reinforcement Selection

39
Cost

⚫ Glass Fibers 1 LB = 453 gram

• E-glass: ~$1/lb
• S-glass: ~$8/lb
⚫ Carbon Fibers
• ~$8-$10/lb
⚫ Kevlar
• ~$20/lb
40
MATRIX FOR COMPOSITES

Le Thai Hung

Department of materials mechanic and Metal-rolling

School of Materials Science and Engineering
Hanoi University of Science and Technology
 OUTLINE
 Roles-function of the matrix materials
 Type of matrix
◼ PMC
◼ MMC
◼ CMC
 Matrix Properties
 Matrix selection
Role-function of the matrix
 Transfer stresses between the fibers
 Provides a barrier against an adverse
environment
 Protect the surface of the fibers from
mechanical abrasion
 Determine inter-laminar shear strength
 Determine damage tolerance of composites
 Determine in-plane shear strength
 Determine heat resistance of composite
Type of matrix
Polymer matrix
Polymer matrix
Polymer matrix
Polymer matrix
Polymer matrix
 Thermosets  Thermoplastics
◼ Advantages ◼ Advantages
 Strong interface bond  Short melt time
 Good chemical  Recyclable
resistance  High fracture toughness
 Processing history ◼ Disadvantages
known
 Poor chemical resistance
◼ Disadvantages  Processing science
 Long cure time unknown for composites
 Not recyclable  High shrinkage
 Brittle
Polymer Matrix Properties
Ceramic Matrix
Ceramic Matrix
Ceramic Matrix
Ceramic Matrix
Carbon Matrix
Metal Matrix
Metal Matrix
Example
Matrix Properties
Properties → choice matrices
 COMPOSITE INTERFACES

Le Thai Hung

Department materials mechanics and Metal-rolling

School of Materials Science and Engineering
Hanoi University of Science and Technology
The fiber-matrix interface

Matrix

Fiber
The fiber-matrix interface
 There is always an interface between constituent phases in a
composite material
 For the composite to operate effectively, the phases must
bond where they join at the interface Third ingredient

Interfaces between phases in a composite material: (a) direct bonding

between primary and secondary phases; (b) addition of a third
ingredient to bond the primary phases and form an interphase.
The fiber-matrix interface
 Interphase consisting of a solution of primary and
secondary phases

Interfaces and interphases between phases in a composite material: (c)

formation of an interphase by solution of the primary and secondary
phases at their boundary.
The fiber-matrix interface: Example
 Dilute suspensions: matrix + one fibre-bundle

10mm

T = 50°C
e2 D33 = 10-2s-1
e3 0 < e33 < 1
e1
The fiber-matrix interface
 The interface between fiber and matrix is
crucial to the performance of the composite -
in particular fracture toughness; corrosion;
moisture resistance.
 Weak interfaces provide a good energy
absorption mechanism - composites have low
strength and stiffness, but high fracture
toughness.
 Strong interface results in a strong and stiff,
but brittle composite.
The fiber-matrix interface
 Adhesion between fiber and matrix is due to
one (or more) of 5 main mechanisms:
◼ Adsorption and wetting
◼ Interdiffusion (autohension)
◼ Electrostatic attraction
◼ Chemical bonding
◼ Mechanical adhesion
Adsorption and wetting
 Depending on the surface energies or surface tensions of the
two surfaces. Glass and carbon are readily wetted by epoxy
and polyester resins, which have lower surface energies.
 Wettability defines the extent to which a liquid will spread
over a solid surface. It will only occur if the viscosity of the
matrix is not too high and if wetting results in a decrease in
the free energy of the system.
 All surfaces have an associated energy and the free energy
per unit area of the solid-gas, liquid-gas and solid-liquid
interfaces are  SG ,  LG and  SL
 Adsorption and wetting


 SG −  SL
- is called a contact angle

cos  =  = 1800 - No wetting takes place

 LG  = 00 - Perfect wetting

00    1800 -asThe degree of wetting increases

 decreases
 Interdiffusion (autohension)
 Diffusion and entanglement of molecules:
The atoms and molecules of the
two components of the composite
may interdiffuse at the interface
to give what is known as reaction
or interdiffusion bonding. For
interfaces involving polymer this
type of bonding can, in simple
terms, be considered as due to the Dd- the diffusion coefficient
intertwining of molecules
Q0- is the activation energy for diffusion
(picture).
D0- is constant
Dd = D0 exp(− Qd / RT ) R- is the gas constant
T- is the temperature
Electrostatic attraction
 Important in the application of coupling
agents. Glass fiber surface may be ionic due
to oxide composition:

Electrostatic bonding occurs between the matrix and the reinforcement when one
surface is positively charged and the other negatively charged (figure).
Chemical bonding
 Between chemical group in the matrix and a
compatible chemical on the fiber surface:

- Chemical bonding is the bond formed between chemical groups on the

reinforcement surface (A) and compatible groups in the matrix (B).
- Not surprisingly the strength of the chemical bond depends on the number
of bonds per unit area and the type of bond.
Mechanical adhesion
 Depending on degree of roughness of fiber surface
 Larger surface area may also increase strength of
chemical bond.

A mechanical interlocking of two surfaces in this figure can lead to reasonable

bond. Clearly, the interlocking is greater and hence the mechanical bonding
more effective, the roungher the interface.
Test for measuring interface strength

• Single fiber tests

• Three point bend tests
• Indentation method
• Single fiber compression test
Test for measuring interface strength
Single fiber test
Test for measuring interface strength
Test for measuring interface strength
Test for measuring interface strength
Results

Strong bonding between fiber and matrix causes cracks

to propagate into the matrix system.
The shape of the fiber breaks can give a significant indication of the strength of the
bond between fiber and matrix. A strong bonding between fiber and matrix often
introduces damage to the matrix in the area around the breaks, and the gaps between
the fiber ends are of the order of the fiber diameter. With increasing stress, most of
them expand but to not more than twice their initial gap length. The deformation into
the resin often starts by forming a V-shape on one side of the fiber break and two
smaller ones on the other side. For very strong interface bonding, extensive crack
propagation into the matrix can occur and also lead to specimen failure
Test for measuring interface strength

For a weak interface system, on the other hand, most of the fiber cracks do not
damage the resin and show immediate widening of the breaking gap. An
example of this can be seen in Figure. Raman spectroscopy confirmed that the
black area is indeed a hollow core apart from the middle where some fiber
fragments can be detected. Some of these gaps became more than 5 times
wider than the fiber diameter with further loading.
Test for measuring interface strength

Results
 Test for measuring interface strength

Three point bend test

P b

S
P/2 P/2

3  PS  3 P 
=  2 =  
2  bh  4  bh 

Fiber pull-out test

Load transfer between matrix
and fiber
 Under applied tension, load is transferred by shear at
the matrix/fiber interface.
Load transfer between matrix
and fiber
 Stress variation in a short fiber
Load transfer between matrix
and fiber
 Stress variation in a short fiber - experimental
evidence
Summary
 The interface is a bounding surface or zone
where a discontinuity occurs, whether physical,
mechanical, chemical, etc.
 More often than not, the interface between fiber
and matrix is rather rough, instead of ideal
planar.
 The matrix material must “wet” the fiber.
Coupling agents are frequently used to improve
wettability. Well “wetted” fibers increase the
interface surface area.
 Summary
 To obtain desirable properties in a composite, the
applied load should be effectively transferred from the
matrix to the fibers via the interface. This means that
the interface must be large and exhibit strong adhesion
between fibers and matrix. Failure at the interface
(called debonding) may or may not be desirable. This
will be explained later in fracture propagation modes.
 Bonding with the matrix can be either weak van der
Walls forces or strong covalent bonds.
Summary

 The internal surface area of the interface can go

as high as 3000cm2/cm3
 Interfacial strength is measured by simple tests
that include adhesive failure between the fibers
and the matrix. The most common is the three-
point bend test or interlaminar shear stress test.
COMPOSITE PROPERTIES

Le Thai Hung
Department of Materials Mechanics and Metal Forming
School of Materials Science and Engineering
Hanoi University of Science and Technology
Introduction

Model of a fiber-reinforced composite

material showing direction in which elastic
In selecting a composite material, modulus is being estimated by the rule of
an optimum combination of mixtures (b) Stress-strain relationships for
properties is usually sought, the composite material and its constituents.
rather than one particular The fiber is stiff but brittle, while the matrix
property (commonly a polymer) is soft but ductile.
Introduction

Variation in elastic modulus and tensile strength as a function of direction of

measurement relative to longitudinal axis of carbon fiber-reinforced epoxy
composite
 Introduction
Determined by three factors:
1. The materials used as component
phases in the composite
2. The geometric shapes of the
constituents and resulting structure of
the composite system
3. The manner in which the phases
interact with one another
Stress – strain relations

 = E
 = G
x =
E
( x +  y ),
1 − 2

y =
E
( x +  y )
1 − 2
Stress – strain relations

◼ In transverse loading the fibers carry less of the load-isostress

c = m =  f = 
 c =  mVm +  f V f
◼ Continuous fibers – Estimate fiber-reinforced composite strength for long
continuous fibers in a matrix
❑ Longitudinal deformation

 c =  mVm +  f V f
c = m =  f
Density
mc = m f + mm Dividing by mc
M f + Mm =1

vc = v f + v m + vc Dividing by vc
V f + Vm + Vv = 1

mc m f + m m  f v f +  m v m
c = = =
vc vc vc

c =  f V f +  mVm Rules of mixtures

 Elastic constants

Longitudinal direction Ecl = E f V f + EmVm = E11

1 Vm V f 1
Transverse direction = + =
E ct E m E f E 22
HOMEWORKS
COMPOSITES PROCESSING
OF PMCs

Le Thai Hung
Department of Materials Mechanic and Metal Rolling (3MR)
School of Materials Science and Enginering (SMSE)
Hanoi University of Science Technology (HUST)

1
 OUTLINE

◼ Introduction
◼ Polymer matrix
◼ Reinforcements
◼ Processing
◼ Properties
◼ Applications
Introduction

◼ The processing of PMCs need not involve high

pressure and does not require high temperature. The
degradation of the reinforcement during manufacture
are less significant for PMCs than other matrices.
◼ The equipment required for PMCs may be simpler.
For these reasons PMCs developed rapidly and soon
became for structure applications.
◼ Moreover, PMCs are their low maximum working
temperature, high coefficient of thermal expansion
and hence dimensional instability and sensitivity to
radiation and moisture.
Matrix

◼ There are two general classes of polymers based on

their behavior when exposed to heat.
❑ Thermoplasts: these plastics soften when heated and harden
when cooled-processes that are totally reversible and may be
repeated.
❑ Thermosets: these plastic require heat and pressure to mold
them into shape. They are formed into a permanent shape and
cured or ‘set’ by chemical reactions such as extensive cross-
linking.
◼ In addition, the epoxy matrix can also used.
Matrix

◼ Thermoplastic: unlimited shelf time; shorter

fabrication time; post-formability; easy to
repair (welding or solvent bonding)
◼ Themosetting: thermal stability; chemical
resistance; less creep and stress relaxation.
◼ Epoxy: wide variety of properties; absence of
volatile matters during cure excellent
resistance to chemicals and solvents but high
cost and long cure time.
Type of matrix
◼ Thermoset ⚫ Thermoplastic
❑ Polyester (UP) – Polyethylene (PE)
❑ Vinylester (VE) – Polypropylene (PP)
❑ Epoxy (EP)
– Polyamide (PA-Nylon)
❑ Phenolic
– Thermoplastic polyester/polyimide
❑ Polyurethane
❑ Thermoset Polyimid – Poly(phenylene Sulfides) (PPS)
– Polyketones (PEK, PEEK)
Comparison of mechanical properties of thermosets/thermoplastics
Thermosets Thermoplastics
Young’s modulus (GPa) 1.3-1.6 1.0-4.8
Tensile strength (MPa) 20-180 40-190
Fracture toughness
- KIC (MPam1/2) 0.5-1.0 1.5-6.0
- GIC (KJ/m2) 0.02-0.2 0.7-6.5
Maximum service temperature 0C 50-450 25-230
Matrix properties
Reinforcements
Reinforcements

◼ Glass fiber-Reinforced polymer (GFRP)

❑ Glass fibers: easy to manufacture, chemical
resistance
❑ Glass fiber surface is coated with a thin polymer
layer, i.e. ‘size’, to protect the fiber surface from
damage
❑ GFRPs’ use temperature is limited below 2000C
due to polymer matrix
❑ Major applications of GFRPs: automotive, marine
vehicle bodies, pipes, storage, containers…
Reinforcements

◼ Carbon fiber-Reinforced polymer (CFRP)

❑ High specific modulus and specific strength
even at high temperature
❑ Good physical and mechanical properties
❑ Expensive manufacturing processes
❑ Diameter: 4-10m, coated with epoxy size to
improve adhesion with matrix
❑ Major applications of CFRPs: aircraft structural
components, sporting goods…
Reinforcements properties
Processing
Seven main processes
◼ Pultrusion
◼ Filament winding
◼ Ply lay-up
◼ Spray lay-up
◼ Compression molding
◼ Injection molding (BMC)
◼ Transfer molding

12
Pultrusion
Introduction
◼ Long fibers are aligned parallel to one another and pulled through a
resin bath.
◼ The wetted fibers are then drawn through a heated die for
polymerization of the resin to form the matrix.
◼ Long, constant cross-section output is produced, can be cut to length.

Materials

◼ Common fibers: glass,

carbon, aramid.
◼ Common matrices:
polyester, vinyl ester,
epoxy, phenolics.

13
Pultrusion – processing
Fiber
racks

Resin bath
Forming – curing
(die) Pulling
system Cut
Roving machine
supply

Preforming

Pultruded
section

http://www.libertypultrusions.com

14
Pultrusion – processing
◼ The pultrusion process allows us to produce continuous
lengths of fibers reinforced polymer (FRP) profiled shapes.
First, fiberglass in the form of continuous roving filaments or
fiber bundles, is draw through the liquid resin, which
saturates the glass reinforcement.
◼ This combination of resin and glass is then pulled through a
special die a continuous pulling device. The mass of
materials conforms to the shape of the die and is heat-set
into a permanent structurally reinforced shape. The resulting
high strength profile is cut to length ready for use when it
leaves the pultrusion machine. Pultruded products provide
manufactures and designers with the benefits of high
strength to weight ratios, corrosion resistance, heat
resistance, dielectric properties, dimension stability and
weatherability. In the end, pultruded products are a cost
effective and versatile alternative to traditional materials.

15
 Pultrusion – Applications
Pultruded structural products Pultruded electrical shapes Pultruded rod

http://www.libertypultrusions.com

16
 Filament winding
Introduction

◼ Fibers are ‘spooled’ onto a rotating mandrel.

◼ The fibers are dragged through a thermoplastic resin as they are applied, which
becomes the matrix when the mandrel is heated after spooling.
◼ Creates precisely oriented composite cylinders with high fiber percentages.

Materials
◼ Common fibers: Glass, carbon,
graphite, metal wire, PP.
◼ Common matrices: polyester, vinyl
ester, epoxy, other thermosets,
PEEK, PPS, other thermoplastics.

17
Filament winding – processing

Schematic of the filament winding process

www.azom.com

18
Filament winding – processing
• High speed precise laying down of resin impregnated continuous fibers onto a
mandrel is the basic of filament winding process.
• The mandrel can be any shape that does not have re-entrance curvature, although it
is possible to remove the component from the mandrel before it has cured and use
some other means of compaction to produce reserve curvature if required.
• Multi axes can also be used.
• The process is usually computer controlled and the reinforcement can be oriented to
match the design loads.
• Components from the small diameter tubes to 40m, 13 tone wind turbine
blades have been manufactured using filament winding
• The fibers may be impregnated with resin before winding (wet winding),
preimpregnated (dry winding) or postimpregnated. Wet winding has the advantages of
using the lowest cost materials with long storage life and low viscosity. The prepreg
system produce parts with more consistent resin content and can often be wound
faster.

19
Filament winding - Applications

Storage tanks, piping, aircraft

fuselages, cylindrical or near
cylindrical objects required high
strength …

20
Pull-winding process

Pullwinding is a method of producing high performance composites tubes

combining the techniques of conventional pulltrusion and continuous filament
winding. Layer of axial fibers and helically wound fibers are companied to
produce a product with an excellence crush strength, high stiffness and superb
torsional properties.
www.pulwellpultrusions.com/applications.htm

21
 Ply lay-up
Introduction
◼ Also called “hand lay-up”
◼ A non-stick mold holds fibers arranged in their final orientation.
◼ Resin is rolled onto the mold, soaking around the fibers, and the setup then
sits to cure.
◼ A single large, customizable object is produced with long-fibered composite.

Materials

◼ Common fibers: Sheets of fiber,

including glass, carbon, or
graphite
◼ Common matrices: epoxy,
polyester, vinyl ester.

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Ply lay-up – processing

The Compoflex products are nonwoven fabrics made from 100% polypropylene.
The fabric consists of two layers: a micro-porous peel-layer and a bleeder-layer,
incorporating the properties of several consumables in one fabric.
http://www.fibertex.com

23
Ply lay-up – processing

24
Ply lay-up – processing

25
Ply lay-up – Applications

Boat hulls, truck beds, wind

turbine blades, aircraft surfaces
…

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Snowboards and skis

27
Ply lay-up – Pros/Cons

◼ Pros
❑ Simple to teach

❑ Low cost tooling

❑ High fiber content, longer fibers than spray lay-up

◼ Cons
❑ Not suitable for mass production

❑ Entrapment of air bubbles causes voids

❑ Low densification and concentration of the reinforcement phase (30 %)

❑ Resins need to be low in viscosity

❑ Must limit hazardous airborne styrene

❑ Low molecular weight resin can be harmful as well

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 Spray lay-up
Introduction

◼ A non-stick mold receives sprays of liquid resin and chopped fiber.

◼ The two mix in the mold and the mixture is smoothed with a roller.
◼ A single large, customizable object is produced, much more quickly
than with the ply lay-up technique, with short-fibered composite.
◼ The mold is waxed, sprayed with gelcoat, and then cured in a heated
oven at 50°C (120º F). After the gelcoat has cured, the mold is
sprayed with a mixture of catalyzed resin and chopped fiberglass
roving (E-glass cut with a chopper gun).

Materials

◼ Common fibers: Almost exclusively chopped glass fiber.

◼ Common matrices: polyester, vinyl ester.

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Spray lay-up – processing

30
Spray lay-up – Applications

◼ Non-load bearing panels

◼ Bath tubs
◼ Shower bases
◼ Short-fibered large, small
quantity, lightly loaded objects
with one finished surface.

31
Spray lay-up – Pros/Cons

◼ Pros
❑ Very low cost compared to close mold processes

❑ Very fast compared with ply lay-up

❑ Better wetting of fibers with few voids than ply lay-up

◼ Cons
❑ Laminates tend to be very heavy

❑ Only short fibers are available

❑ Resin needs to have a low viscosity

❑ Parts are less uniform in thickness than ply lay-up

❑ Only one smooth UV protected side

❑ Must be trimmed

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 Compression molding (SMC-BMC)
Introduction

Materials
◼ Common fibers:
glass fiber.
◼ Common matrices:
polyester, vinyl ester.

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Compression molding
Pros/cons
◼ Pros
❑ Very good dimensional uniformity and thickness consistency

❑ Parts are superior to those of the lay-up processes in every area of

strength
❑ UV protection throughout the part, not just on one surface like with lay-up

❑ Faster production than most processes

❑ Class A finish on both surfaces

❑ Parts are extremely strong and durable

◼ Cons
❑ Longer than injection molding cycles

❑ High initial capital investment

❑ Complex shapes hard to produce

❑ Parts cannot be reformed

34
Injection molding BMC

35
Injection molding BMC

◼ Produced from any conventional

thermoset matrix systems
◼ The part can be formed as soon as the
BMC compound is mixed
◼ Differs from sheet molding compound
in that BMC consists of small randomly
oriented fibers
◼ When used in RTM, the BMC takes the
place of the resin that is to be injected
❑ There is not preformed fiber
reinforcement in the mold here

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Resin Transfer Molding (RTM)

37
 Resin Transfer Molding (RTM)
◼ Close molding process
◼ Intermediate between slow lay-up
processes and quick compression
molding processes
◼ Medium volume production
◼ Produces complex small parts
◼ Process
❑ Both female and male mold are
covered in gel coating
❑ Reinforcing fabric material is placed in
the female mold
❑ Mold is closed & a predetermined
amount of preheated resin is slowly
injected into the mold
❑ Typically cured with heat and
pressure, but can also be cured at
room temperature
❑ Removed by ejector pins

38
 Resin Transfer Molding (RTM)
Materials

◼ Reinforcement
❑ Any fibers

◼ Resin Matrices
❑ Usually thermosetting

❑ Epoxy

❑ Polyester

❑ Vinyl ester

❑ Phenolic

39
RTM
Applications

◼ Small complex aircraft and

automotive parts
◼ Train seats
◼ Truck roof caps

40
Resin Transfer Molding – Pros/Cons

◼ Pros
❑ Very good reproducible wall thickness and resin/fiber ratios

❑ High fiber volume with very few voids

❑ Good health and safety

❑ Both sides of the part are a good finish

❑ Very little labor required
❑ Cycle time is shorter than lay-up and compression processes

❑ Makes more complex parts than compression molding

❑ Mold price is lower than compression molding

◼ Cons
❑ Tooling is heavy and expensive compared with lay-up

❑ Usually limited to smaller components

❑ Quality of impregnation can not be known until the part is finished

❑ Cycle time is slower than injection molding

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Properties

Comparison of unidirectional mechanical properties of epoxies

reinforced with various fiber.
Strength (MPa) Young’s Density
Fiber Modulus (Mg/m3)
Tensile Compressive (GPa)
E-glass 1165 490 50 1.99
S-glass 1750 495 60 1.99
Carbon (AS4) 1480 1225 145 1.55
Carbon (HMS) 1275 1020 205 1.63
Aramid 1310 290 85 1.38
Applications