INTRODUCTION COMPOSITE MATERIALS AND APPLICATIONS ENGINEERING MATERIALS 11/10/2015 OUTLINE. Kendari, 8 Oktober 2015

Size: px

Start display at page:

Download "INTRODUCTION COMPOSITE MATERIALS AND APPLICATIONS ENGINEERING MATERIALS 11/10/2015 OUTLINE. Kendari, 8 Oktober 2015"

Bertina Simpson
6 years ago
Views:

OUTLINE INTRODUCTION COMPOSITE MATERIALS: Classes and types of composites Strength of composites Composite productions APPLICATIONS Kendari, 8 Oktober 2015 2 ENGINEERING MATERIALS INTRODUCTION

1 Prodi TEKNIK MESIN UNIVERSITAS HALUOLEO COMPOSITE MATERIALS AND APPLICATIONS Prof. Ir. Hadi Sutanto, MMAE., Ph.D. OUTLINE INTRODUCTION COMPOSITE MATERIALS: Classes and types of composites Strength of composites Composite productions APPLICATIONS Kendari, 8 Oktober ENGINEERING MATERIALS INTRODUCTION METALS: FERROUS & NON FERROUS CERAMICS & GLASSES POLYMERS & ELASTOMERS COMPOSITES History of Materials Science & Engineering materials closely connected our culture the development and advancement of societies are dependent on the available materials and their use early civilizations designated by level of materials development History of Materials Science & Engineering initially natural materials develop techniques to produce materials with superior qualities (heat treatments and addition of other substances) 6 1

Brick : Ramses II, EGYPT 1279-1212 BC Material production Concern 1: Resource consumption, dependence 96% of all material

Carbon to atmosphere Concern 2: Energy consumption, CO 2 emission 20% of all carbon to atmosphere Why study materials?

economics BUT really, everyone makes material choices! Sources: Granta Design, Cambridge, UK.

subatomic atomic microscopic macroscopic (bulk) processing method of preparing material characterization performance

2 Brick : Ramses II, EGYPT BC Material production Concern 1: Resource consumption, dependence 96% of all material Usage 20% of Global energy Sources: Granta Design, Cambridge, UK. Carbon to atmosphere Concern 2: Energy consumption, CO 2 emission 20% of all carbon to atmosphere Why study materials? applied scientists or engineers must make material choices materials selection in-service performance deterioration economics BUT really, everyone makes material choices! Sources: Granta Design, Cambridge, UK. aluminum glass plastic Materials Science and Engineering TETRAHEDRON structure arrangement of internal components subatomic atomic microscopic macroscopic (bulk) processing method of preparing material characterization performance behavior in a particular application properties material characteristic response to external stimulus mechanical, electrical, thermal, magnetic, optical, deteriorative Bro oks/cole Pub lishing / Tho mso n Learning 12 2

Processing, & Properties Properties depend on structure ex: hardness vs structure of steel Hardness (BHN) 600 500 400 300 200 (a) 30 mm (b) 30 mm 100 0.01 0.

3 Application of the tetrahedron of materials science and engineering to sheet steels for automotive chassis. Note that the microstructure-synthesis and processing-composition are all interconnected and affect the performance-to-cost ratio Bro ok s/cole Pub lishing / Tho mso n Learning Structure, Processing, & Properties Properties depend on structure ex: hardness vs structure of steel Hardness (BHN) (a) 30 mm (b) 30 mm Cooling Rate (ºC/s) Processing can change structure ex: structure vs cooling rate of steel (c) 4 mm (d) 30 mm Data obtained from Figs (a) and with 4 wt% C composition, and from Fig and associated discussion, Callister 7e. Micrographs adapted from (a) Fig ; (b) Fig. 9.30;(c) Fig ; and (d) Fig , Callister 7e. 14 The Materials Selection Process 1. Pick Application Determine required Properties Properties: mechanical, electrical, thermal, magnetic, optical, deteriorative. 2. Properties Identify candidate Material(s) Material: structure, composition. COMPOSITE MATERIALS 3. Material Identify required Processing Processing: changes structure and overall shape ex: casting, sintering, vapor deposition, doping forming, joining, annealing. 15 Composites Combine materials with the objective of getting a more desirable combination of properties Ex: get flexibility & weight of a polymer plus the strength of a ceramic Venn diagram of three basic material types plus composites Principle of combined action Mixture gives averaged properties 18 3

Some examples of composite materials: (a) plywood is a laminar composite of layers of wood veneer, (b) fiberglass is a fiber-reinforced composite containing

matrix (reduced 50%). Terminology Composites: -- Multiphase material w/significant proportions of each phase.

ceramic polymer Dispersed phase: -- Purpose: enhance matrix properties. MMC: increase y, TS, creep resist.

5 mm Reprinted with permission from D. Hull and T.W. Clyne, An Introduction to Composite Materials, 2nd ed., Cambridge University Press, New York, 1996, Fig.

4 Some examples of composite materials: (a) plywood is a laminar composite of layers of wood veneer, (b) fiberglass is a fiber-reinforced composite containing stiff, strong glass fibers in a softer polymer matrix ( 175), and (c) concrete is a particulate composite containing coarse sand or gravel in a cement matrix (reduced 50%). Terminology Composites: -- Multiphase material w/significant proportions of each phase. Matrix: -- The continuous phase -- Purpose is to: - transfer stress to other phases - protect phases from environment -- Classification: MMC, CMC, PMC metal ceramic polymer Dispersed phase: -- Purpose: enhance matrix properties. MMC: increase y, TS, creep resist. CMC: increase Kc PMC: increase E, y, TS, creep resist. -- Classification: Particle, fiber, structural woven fibers 0.5 mm cross section view 0.5 mm Reprinted with permission from D. Hull and T.W. Clyne, An Introduction to Composite Materials, 2nd ed., Cambridge University Press, New York, 1996, Fig. 3.6, p Particle-reinforced Composite Survey Largeparticle Dispersionstren gthened Continuous (aligned) Comp osites Fiber-reinforced Discontinuous (short) Aligned Randomly oriented Laminates Structura l Sandwich panels Adapted from Fig. 16.2, Callister 7e. 24 4

5 Composite Survey: Particle-I Composite Survey: Particle-II Examples: - Spheroidite matrix: steel ferrite (a) (ductile) - WC/Co cemented carbide - Automobile tires 60 mm matrix: cobalt (ductile) V m : vol%! 600 mm matrix: rubber (compliant) 0.75 mm particles: cementite (Fe 3 C ) (brittle) particles: WC (brittle, hard) particles: C (stiffer) Adapted from Fig , Callister 7e. (Fig is copyright United States Steel Corporation, 1971.) Adapted from Fig. 16.4, Callister 7e. (Fig is courtesy Carboloy Systems, Department, General Electric Company.) Adapted from Fig. 16.5, Callister 7e. (Fig is courtesy Goodyear Tire and Rubber Company.) 25 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 Prestressed 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 nut threaded rod 26 Composite Survey: Particle-III Elastic modulus, Ec, of composites: -- two approaches. upper limit: rule of mixtures Data: Cu matrix w/tungsten particles E(GPa) E c = V m E m + V p E p lower limit: 1 = Vm + V p E c E m E p 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. Adapted from Fig. 16.3, Callister 7e. (Fig is from R.H. Krock, ASTM Proc, Vol. 63, 1963.) 27 Composite Survey: Fiber-I 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 28 Composite Survey: Fiber-II Fiber Materials Whiskers - Thin single crystals - large length to diameter ratio graphite, SiN, SiC high crystal perfection extremely strong, strongest known very expensive Fiber Alignment Adapted from Fig. 16.8, Callister 7e. Fibers polycrystalline or amorphous generally polymers or ceramics Ex: Al 2O 3, Aramid, E-glass, Boron, UHMWPE Wires Metal steel, Mo, W 29 aligned continuous aligned random discontinuous 30 5

6 Composite Survey: Fiber-III Composite Survey: Fiber-IV Aligned Continuous fibers Examples: -- Metal: g'(ni3al )-a(mo) -- Ceramic: Glass w/sic fibers by eutectic solidification. formed by glass slurry matrix: a (Mo) (ductile) Eglass = 76 GPa; ESiC = 400 GPa. 2 mm fibers: g (Ni 3 Al ) (brittle) From W. Funk and E. Blank, Creep deformation of Ni3Al-Mo in-situ composites", Metall. Trans. A Vol. 19(4), pp , Used with permission. (a) (b) fracture surface From F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, (a) Fig. 4.22, p. 145 (photo by J. Davies); (b) Fig , 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 Other variations: -- Discontinuous, random 3D -- Discontinuous, 1D (a) fibers lie in plane Adapted from F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, (a) Fig. 4.24(a), p. 151; (b) Fig. 4.24(b) p (Courtesy I.J. Davies) Reproduced with permission of CRC Press, Boca Raton, FL Composite Survey: Fiber-V Critical fiber length for effective stiffening & strengthening: fiber strength in tension fiber diameter f fiber length 15 d shear strength of c fiber-matrix interface Ex: For fiberglass, fiber length > 15 mm needed Why? Longer fibers carry stress more efficiently! Shorter, thicker fiber: Longer, thinner fiber: fiber length 15 fd fiber length 15 c c (x) (x) Poorer fiber efficiency Adapted from Fig. 16.7, Callister 7e. f d Better fiber efficiency 33 Composite Strength: Longitudinal Loading Continuous fibers - Estimate fiber-reinforced composite strength for long continuous fibers in a matrix Longitudinal deformation c = m V m + f V f volume fraction but e c = e m = e f isostrain E ce = E m V m + E f V f longitudinal (extensional) modulus Ff EfVf f = fiber F E V m = matrix m m m 34 Composite Strength: Transverse Loading In transverse loading the fibers carry less of the load - isostress c = m = f = 1 E ct V E m m Vf E f e c = e m V m + e f V f transverse modulus Composite Strength Estimate of Ec and TS for discontinuous fibers: f -- valid when fiber length 15 d c -- Elastic modulus in fiber direction: E c = E m V m + KE f V f efficiency factor: -- aligned 1D: K = 1 (aligned ) -- aligned 1D: K = 0 (aligned ) -- random 2D: K = 3/8 (2D isotropy) -- random 3D: K = 1/5 (3D isotropy) Values from Table 16.3, Callister 7e. (Source for Table 16.3 is H. Krenchel, Fibre Reinforcement, Copenhagen: Akademisk Forlag, 1964.) -- TS in fiber direction: (TS) c = (TS) m V m + (TS) f V f (aligned 1D)

Composite Production Methods-I Pultrusion Continuous fibers pulled through resin tank, then preforming die & oven to cure Composite Production Methods-II

Hancox, (Editor), Fibre Composite Hybrid Materials, The Macmillan Company, New York, 1981.] Adapted from Fig. 16.13, Callister 7e.

Comparison of the yield strength of dispersionstrengthened sintered aluminum powder (SAP) composite with that of two conventional two-phase high-strength

2003 Brooks/C ole, a divis ion of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license.

Composite Survey: Structural Stacked and bonded fiber-reinforced sheets -- stacking

7 Composite Production Methods-I Pultrusion Continuous fibers pulled through resin tank, then preforming die & oven to cure Composite Production Methods-II Filament Winding Ex: pressure tanks Continuous filaments wound onto mandrel Adapted from Fig , Calister 7e. [Fig is from N. L. Hancox, (Editor), Fibre Composite Hybrid Materials, The Macmillan Company, New York, 1981.] Adapted from Fig , Callister 7e Brooks/C ole, a division of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license. Comparison of the yield strength of dispersionstrengthened sintered aluminum powder (SAP) composite with that of two conventional two-phase high-strength aluminum alloys. The composite has benefits above about 300 C. A fiber-reinforced aluminum composite is shown for comparison Brooks/C ole, a divis ion of Thomson Learning, Inc. Thomson Learning is a trademark used herein under license. A comparison of the specific modulus and specific strength of several composite materials with those of metals and polymers. Composite Survey: 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 , Callister 7e. Adapted from Fig , Callister 7e. (Fig is from Engineered Materials Handbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.) 41 7

Composite Materials Hexagonal core OxCore-over

formability Composite Benefits 10-4 CMCs: Increased

3 ceramics E(GPa) 10 2 PMCs 10 metal/ fiber-reinf 1

1 G=3E/8 polymers Bend displacement K=E.01.1.3 1 3 10

10-6 Increased creep resistance 10-8 6061 Al w/sic

G. Nieh, "Creep rupture of a silicon-carbide

15(1), pp. 139-146, 1984. Used with permission.

8 Composite Materials Hexagonal core OxCore-over expanded in height core FlexCore-exceptional formability Composite Benefits 10-4 CMCs: Increased toughness PMCs: Increased E/r Force particle-reinf 10 3 ceramics E(GPa) 10 2 PMCs 10 metal/ fiber-reinf 1 metal alloys un-reinf.1 G=3E/8 polymers Bend displacement K=E Density, r [mg/m 3 ] MMCs: 6061 Al ess (s -1 ) 10-6 Increased creep resistance Al w/sic whiskers (MPa) Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp , Used with permission. 45 APPLICATIONS Some Applications of Composite Materials Current Markets and Applications Sources: SPI Composite Institute 8

9 Rocket ARIANNE V Static test in EMPA Switzerland Waterfront Structure and Decking Industry Bridge decks The Lion Gate Bridge, Vancouver, Canada Highway Structure Guard Rail Auto Skyway Posts Deck weight comparison per SF 9

10 FRP Composite Utility Poles Pressure Vessel Pipes Composite Turbine Blades for Wind Energy Pipeline Infratructure Materials of Brake Pads 10

Natural Fibers Why Composites Inspection?

to premature failure Composites fail in catastrophically with little or no warning (different manner

Infrared - Shearography - Thermography Destructive Testing - Coupon Testing Summary Composites are

PMC: enhance E, y, TS, creep performance Particulate-reinforced: -- Elastic modulus can be estimated.

11 Natural Fibers Why Composites Inspection? Much larger percentage of using composites in the world Need to detect discontinuities that may lead to premature failure Composites fail in catastrophically with little or no warning (different manner than metals) Classifications of Inspections Nondestructive Inspection - Visual - Ultrasonic - Infrared - Shearography - Thermography Destructive Testing - Coupon Testing Summary Composites are classified according to: -- the matrix material (CMC, MMC, PMC) -- the reinforcement geometry (particles, fibers, layers). Composites enhance matrix properties: -- MMC: enhance y, TS, creep performance -- CMC: enhance Kc -- PMC: enhance E, y, TS, creep performance Particulate-reinforced: -- Elastic modulus can be estimated. -- Properties are isotropic. Fiber-reinforced: -- Elastic modulus and TS can be estimated along fiber dir. -- Properties can be isotropic or anisotropic. Structural: -- Based on build-up of sandwiches in layered form. Applications and Inspections 66 11

12 Sources: Materials Science and Engineering: An Introduction W.D. Callister, Jr., 8th edition, John Wiley and Sons, Inc. (2010). The Science and Engineering of Materials, 4 th ed Donald R. Askeland Pradeep P. Phulé (2007) Introduction to Materials Science for Engineers, J.F. Shackelford, Prentice Hall International, Inc., (1996). Principles and Composite Material Mechanics, Ronald F. Gibson, McGraw-Hill Inc., (1994). Mechanics of Composite Materials, Robert M. Jones, Taylor & Francis, (1999). Thank You for Your Attention 67 12

Materials Sci. And Eng. by W.D.Callister Chapter 16: Composite Materials

Materials Sci. And Eng. by W.D.Callister Chapter 16: Composite Materials ISSUES TO ADDRESS... What are the classes and types of composites? Why are composites used instead of metals, ceramics, or polymers?