Module 5-Materials and Composites
Module 5-Materials and Composites
Types of Stress
Tensile Stress
The external force per unit area of the material resulting in the stretch of the
material is known as tensile stress.
Compressive Stress
Compressive stress is the force that is responsible for the deformation of the
material, such that the volume of the material reduces.
What is Strain?
• Strain is the amount of deformation experienced by the body in the direction of force
applied, divided by the initial dimensions of the body.
• Strain ϵ = δl / L
• where ε is the strain due to the stress applied, δl is the change in length and L is the
original length of the material.
• The strain is a dimensionless quantity as it just defines the relative change in
shape.
Types of Strain
Tensile Strain
The deformation or elongation of a solid body due to applying a tensile force or stress
is known as Tensile strain. In other words, tensile strain is produced when a body
increases in length as applied forces try to stretch it.
Compressive Strain
Compressive strain is the deformation in a solid due to the application of compressive
stress. In other words, compressive strain is produced when a body decreases in
length when equal and opposite forces try to compress it.
Stress-strain relationship, plot
• Each material curve possesses different transition points, i.e. from elasticity to
plasticity and finally to breakage.
• The point at which the material transforms from elastic to plastic is known as
the yield point.
Young’s
Shear modulus Bulk modulus
Material modulus (E) in
(G) in GPa (K) in GPa
GPa
Glass 55 23 37
Steel 200 84 160
Iron 91 70 100
Lead 16 5.6 7.7
Aluminium 70 24 70
Tensile strength:
• Tensile strength is the maximum load that a material can support without
fracture when being stretched, divided by the original cross-sectional area of
the material.
• Tensile strengths have dimensions of force per unit area.
• It measures the strength of the materials.
Creep and Creep strength
• A material behaves differently when subjected to an instantaneous high stress
or a constant stress for a certain amount of time.
1. Primary Creep
This initial stage is when elastic
deformation begins to occur. Afterwards,
plastic deformation takes over, as the
creep slows down from its initial fast rate
due to a process called strain hardening
(or work hardening), where the material is
strengthened by plastic deformation.
2. Secondary Creep
This stage is also called the steady-state
creep. It takes place as the strain rate
starts to settle into a constant state. Strain
is comparatively slow, as microstructural
damage has not been reached yet.
3. Tertiary Creep
This is the final stage in a material’s creep deformation, where deterioration in
the material’s microstructure comes about. This continuous damage causes the
strain to pick up speed and worsen until sufficient voids in the microstructure
are generated, resulting in the material failing in a fracture.
A graph showing the effects of temperature and stress on creep deformation.
Hardness
• Hardness is a metric that measures how resistant a material is to localised plastic deformation caused by
mechanical indentation or abrasion. It has important diagnostic properties in mineral identification or abrasion.
• Hardness describes the resistance that a material exhibits to permanent indentation or marking by scratches. Hardness is
not a material property, rather a value ascribed to a material as a result of empirical testing. There are six main hardness
tests that can be carried out: Vickers, Rockwell, Brinell, Mohs, Shore and Knoop. Which one to apply depends on the type
of material to be tested and the equipment available. Most hardness tests involve using machinery that indents the material
over a certain time period, applying a predetermined force or loading.
• There is a general bounding between hardness and chemical composition, thus most hydrous minerals like
halides, carbonates, sulfates, and phosphates are relatively soft. Sulfides are relatively most soft (two exceptions
being marcasite and pyrite) and silicates are hard and most anhydrous oxides. In general, the different materials
have different hardness.
• For example, hard metals like titanium and beryllium are harder than soft metals like sodium and metallic tin, or
wood and normal plastics.
• Powerful intermolecular bonds are commonly used to identify macroscopic hardness, but the structure of solid
materials under stress is more complicated.
• In addition, there are different measurements of hardness such as scratch hardness, indentation hardness, and
rebound hardness
• Hardness is based on plasticity, ductility, elastic stiffness, strain, strength, toughness, viscosity, and
viscoelasticity. For example, polymers and elastomers, it is defined as the resistance to elastic distortion of the
surface.
• Scratch Hardness
• Scratch hardness is a measurement of a sample's resistance to fracture or permanent plastic deformation
caused by pressure from a sharp edge. An object made by a tougher material will scratch an object made by a
softer material, according to the theory. Scratch hardness refers to the force used to break through the film to the
substrate when examining coatings. Sclerometer is a tool that is used for the measurement of scratch hardness.
• Indentation Hardness
• The resistance of a sample to material deformation caused by a steady compression load from a sharp object is
measured by indentation hardness. Indentation hardness test is primarily used in engineering fields and
metallurgy fields. Indentation tests are based on the principle of calculating the essential dimensions of an
indentation created by special dimensions and loaded indenter.
• Scratch Hardness
• Indentation Hardness
Fatigue
• Materials have been known to fail in service under repetitive stresses that are much lower than their
tensile strength. It’s estimated that about 90% of mechanical failures of materials in service are caused
by or at least contributed to by fatigue.
• Therefore, fatigue is an important parameter to consider for moving mechanical components that
are expected to last for long periods.
What is fatigue strength?
• Mechanical fatigue: from fluctuating stresses and strains
• Creep fatigue: as a result of cyclic stresses at elevated temperatures
• Thermal fatigue: from repeated changes in temperature
• Thermo-mechanical fatigue: a combination of thermal and mechanical fatigue
• Fretting fatigue: fatigue due to frictional wear
• Corrosion fatigue: resulting from cyclic stresses under corrosive conditions
• Fatigue strength, however, generally refers to mechanical fatigue, and it is defined as the stress level
below which there would be no fatigue failure even if there were to be a certain very high number
of stress cycles applied to a material. This mechanical stress can be either axial stress, torsional stress
or flexural stress. Fatigue strength is often used interchangeably with fatigue limit or endurance limit,
but they are not strictly the same thing.
• Fatigue limit is a stress level below which there would be no fatigue failure no matter the number of
load cycles the material is subjected to. But since it is impossible to test a material for an infinite
number of cycles, the fatigue limit is an assumption deduced from testing results. It should be noted
that some materials, such as aluminium and copper, do not have an endurance limit because they will
always eventually fail from fatigue when subjected to a certain number of cyclic loading regardless of
how small the load is. Therefore, the fatigue strengths of such materials are usually calculated as the
stress levels they can endure without failing at a large total number of cycles, usually 5x108 cycles
• A material that is operating under cyclic loads below its fatigue strength will be expected never to fail
as a result of fatigue alone for a certain number of specified loading cycles.
Calculation of Young’s modulus simple exercises
1. A wire with a radius of 5mm is hung freely from the ceiling.
A load of 5N is applied to its free end. Find the elongation in
the wire if its volume is 7.85*10-5m3 & young’s modulus is
1011N/m2.
a) 6.21*10-7m
b) 7.00*10-7m
c) 6.36*10-7m
d) 8.00*10-9m
Stress = Y*strain.
F/A = Y*Δl / l.
Δl = F/A * l/Y = (5/πr2)*(1/1011)
= 6.37*10-7m
1. A wire has a young’s modulus of 105N/m2, length 1m & radius 3mm. Assuming a
uniform cross sectional area, find the radius of wire after it is under a force of 1N
from both ends.
a) 2.58m
b) 2.30m
c) 3.54m
d) 2.24m
Stress = Y*Strain
Δl = F/A * l/Y = (1/2.82*10-5)*(1/105) = 0.35m
As volume will remain same (we can also say that product of l & r2 will be constant as other
terms in expression of volume are constants).
1*32 = 1.35*R2
⇒R = 2.58m.
In the given system, masses are released from rest. The young’s modulus of wire is
1011N/m2, length = 1m & radius = 2mm. Find elongation in wire when masses are moving.
a) 1.05*10-5m
b) 2*10-5m
c) 3*10-5m
d) 0.5*10-5m
• High flexibility
• Easy to fabricate
• Low maintenance
• Yet, they suffer from some deficiencies as in strength and stiffness. To make
up for those deficiencies, reinforcements are integrated into polymer
materials to enhance their mechanical properties.
What is a polymer matrix composite?
• Aside from the types of matrix and reinforcement used, other factors
affecting the properties of a PMC are the constituents’ relative proportions,
the reinforcement geometry and the nature of the interphase.
Thermal
Improved Thermal
Density Control Expansion
processing Conductivity
Control
Flame Greater Impact
Cost reduction
retardancy toughness resistance
Fatigue Fracture Abrasion Corrosion
resistance resistance resistance resistance
High specific High specific
Improved High creep
strength to stiffness to
fatigue strength resistance
weight ratio weight ratio
Despite these many desirable qualities, polymer matrix composites are limited to
service temperatures below 600° F (316° C), above which, polymers start to
degrade [3].
What is a PMC used for?
PMCs are regarded due to their low cost and straightforward fabrication methods.
Automotive industry - Body panels, leaf springs, driveshaft, bumpers, doors, racing car
bodies, and so on.
Aircraft and aerospace industry - Used in the construction of structural parts for military
aircraft, space shuttles, and satellite systems. The main purposes of using PMCs are to reduce
aircraft weight, which can improve its performance, and to reduce its costs.
Marine - Fibreglass boat bodies, as well as canoes and kayaks.
Sports goods - Used in performance footwear, sports equipment and other sporting goods
because of their lightweight and high-strength properties.
Biomedical applications - Medical implants, orthopaedic devices, MRI scanners, X-ray tables,
and prosthetics.
Electrical - Panels, housing, switchgear, insulators, and connectors. It also covers electronic
devices like capacitors, Li-ion and flexible batteries and covers for digital portable equipment
like headphones, etc.
Protective equipment - Since polymer matrix composites can withstand extreme hot or cold
and other hazardous conditions, they are often made as raw materials for bulletproof vests and
other armour.
Industrial - Chemical storage tanks, pressure vessels, pump housing, and valves. PMCs are
also used in impellers, blades, blower and pump housings, and motor covers.
Structural - Polymer matrix composites are used to repair bridges and other construction
materials and equipment like booms and cranes.
Examples of PMCs (polymer matric composite)
• Properties of fiber
• Properties of matrix
• Freshly drawn fibers are coated with matrix material that protect the surface from
damage and other undesirable interactions
• It also helps in promoting a better bond between the fibers and matrix materials.
• Glass fibers are available in the form of mats, tapes, cloth, continuous and chopped
filaments, roving and yarn.
• Applications: automotive parts, marine bodies, storage tanks, plastic pipes, industrial
flooring, high capacity storage tanks, roofing laminate, door and window canopies.
Carbon/graphite Fibers Reinforced Plastics (CRP):
• Matrix: polymer
• Reinforced phase: carbon/graphite fiber
• They have modulus in the range of 200 -900 GPa in the direction parallel to fibers
(along the axis) and 15 GPa in transverse direction.
• Carbon fibers are brittle, strength depend on their internal structures and distribution
in the matrix.
• Applications: sport equipment, motor cases, vessels, air craft components, civil
engineering applications e.g bridges.
Preparation of Carbon fiber:
• New breed of high strength composite material.
• Contain 90 % carbon obtained by the controlled pyrolysis of appropriate fibers.
• Large variety of fibers called precursors used to produced carbon fibers of different
morphologies and different characteristics.
• Most prevalent precursors are polyaacronitrile (PAN), cellulose (viscose, rayon,
cotton), petroleum or coal tar pitch and certain phenolic fibers.
• Manufacture:
• by controlled pyrolysis of organic precursors in fibrous form.
• Basically it removes O2, N2 and H2 to form carbon fibers
• Mechanical properties improved by increasing crystallinity, orientation and
decreasing defects
Applications of kevlar:
• Light weight boat hulls, aircraft fuselage, high performance race cars, bullet proof vest
and puncture resistant tyres.
Demerits:
• Fibre themselves absorb moisture, so kevlar composites are sensitive to the
environment than glass or graphite composites.
• Although tensile and modulus are high, compressive properties are relatively poor.
Applications of FRP:
• Paper Industries
• Metals and mining and construction Industries
• Power station and chemical industry
• Oil and gas industry
• Air pollution
• Medical applications
• Satellites and launch vehicles
• Aircraft structures
• Marine applications
• Automobile Industry
Examples of particle reinforced composites
Metal Matrix composites (MMCs)
• The base material is a metal matrix, while the other substance appears
as fibres or particulates to work as reinforcing material.
Aluminium MMC
These composites make use of aluminium as the base metal matrix.
Examples include SupremEX® 620XF T5 Precision Extrusion (6061B), aluminium-
graphite composite, and aluminium-beryllium composites such as AlBeMet® AM162
HIP.
Magnesium MMC
Magnesium is another excellent matrix material for composites. Some products in
this category include magnesium-silicon carbide (Mg-SiC), magnesium-
aluminium oxide (Mg-Al2O3) and magnesium-titanium carbide (Mg-TiC).
Titanium MMC
Pure titanium is already a strong material in itself, but its composite form may
enhance its superior strength.
Other MMCs
Other less common but highly useful matrix base materials used for composites
include copper, cobalt, nickel, or a combination of metals. Meanwhile, some of the
most common reinforcing materials used are carbon fibre, silicon carbide, alumina,
and boron.
Applications of Metal Matrix Composites
Sports
The superior strength-to-weight ratio of most metal matrix composites
makes the material suitable for tennis rackets, bicycle frames, and other
sports that involve speed and strength.
Automotive Applications
Car and motor racing make use of metal matrix composites for engine and
vehicle body parts due to the lightweight nature of the material.
Applications of Aluminum MMCs:
Applications:
What are ceramic matrix composites (CMCs)?
• Ceramic matrix composites (CMC) are generally made from ceramic fibres or
whiskers embedded in a ceramic matrix.
• These ceramics cover a varied range of inorganic materials that are usually
non-metallic and commonly used at high temperatures.
•Nuclear power industry – including internal reactor structures made from MAX
phase composites that can withstand high temperatures and have high
mechanical damage tolerance and good chemical compatibility with coolants
such as sodium and molten lead.
Ceramic Matrix composites
(CMCs)