COMPOSITE MATERIALS. Asst. Prof. Dr. Ayşe KALEMTAŞ

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1 COMPOSITE MATERIALS Office Hours: Tuesday, 16:30-17:30 Phone: Metallurgical and Materials Engineering Department

2 ISSUES TO ADDRESS Reinforcement Materials Reinforcement-Matrix Interactions Composite material design

3 Reinforcements 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 Possible physical shapes of imbedded phases in composite materials: (a) fiber, (b) particle, and (c) flake 2002 John Wiley & Sons, Inc. M P Groover, Fundamentals of Modern Manufacturing 2/e

4 FIBERS Filaments of reinforcing material, usually circular in cross-section Diameters range from less than mm to about 0.13 mm, depending on material Filaments provide greatest opportunity for strength enhancement of composites The filament form of most materials is significantly stronger than the bulk form As diameter is reduced, the material becomes oriented in the fiber axis direction and probability of defects in the structure decreases significantly

5 Continuous versus Discontinuous Fibers Continuous fibers - very long; in theory, they offer a continuous path by which a load can be carried by the composite part Discontinuous fibers (chopped sections of continuous fibers) - short lengths (L/D = roughly 100) Important type of discontinuous fiber are whiskers - hairlike single crystals with diameters down to about mm ( in.) with very high strength

6 Particles and Flakes A second common shape of imbedded phase is particulate, ranging in size from microscopic to macroscopic Flakes are basically two-dimensional particles - small flat platelets The distribution of particles in the composite matrix is random, and therefore strength and other properties of the composite material are usually isotropic. Strengthening mechanism depends on particle size

7 Fiber Orientation The fibers may be oriented randomly within the material, but it is possible to arrange for them to be oriented preferentially in the direction expected to have the highest stresses. Such a material is said to be anisotropic (different properties in different directions), and control of anisotropy is an important means of optimising the material for specific applications. At a microscopic level, the properties of these composite are determined by the orientation and distribution of the fibers, as well as by the properties of the fiber and matrix materials. These topic known as composite micromechanics is concerned with developing estimates of the overall material properties from these parameters.

8 Fiber Orientation One-dimensional reinforcement, in which maximum strength and stiffness are obtained in the direction of the fiber Planar reinforcement, in some cases in the form of a two-dimensional woven fabric Random or three-dimensional in which the composite material tends to possess isotropic properties Fiber orientation in composite materials: (a) one-dimensional, continuous fibers; (b) planar, continuous fibers in the form of a woven fabric; and (c) random, discontinuous fibers

9 Fiber Orientation

10 Fiber Orientation A three dimensional weave is also possible This could be found when fabrics are knitted or weaved together

11 Fiber Orientation The properties of fiber composites can be tailored to meet different loading requirements By using combinations of different fiber orientation quasi-isotropic materials may be produced Figure. (a) shows a unidirectional arrangement (b) shows a quasi-isotropic arrangement

12 Fiber Orientation Strongest, but anisotropic Weaker, but isotropic

13 Fiber Orientation Maximum strength is obtained when long fibers are oriented parallel to the applied load The effect of fiber orientation and strength can be seen in the plot

14 FIBERS COMMERCIALLY AVAILABLE FORMS OF REINFORCEMENT Filament: a single thread like fiber Roving: a bundle of filaments wound to form a large strand Chopped strand mat: assembled from chopped filaments bound with a binder Continuous filament random mat: assembled from continuous filaments bound with a binder Many varieties of woven fabrics: woven from rovings

15 Fiber Materials Materials for Fibers Metals Steel Polymers Kevlar Ceramics SiC and Al 2 O 3 Carbon High elastic modulus Boron Very high elastic modulus Glass Most widely used filament The most important commercial use of fibers is in polymer composites

16 FIBERS COMMERCIALLY AVAILABLE FORMS OF REINFORCEMENT Roving Filaments Close up of a roving

17 FIBERS COMMERCIALLY AVAILABLE FORMS OF REINFORCEMENT Random mat and woven fabric (glass fibers)

18 FIBERS COMMERCIALLY AVAILABLE FORMS OF REINFORCEMENT Carbon fiber woven fabric

19 FIBERS NEXTEL FIBERS

20 FIBERS NANO FIBERS Comparison - human hair, pollen grain, nanofibers Nanofibers (PA6) x magnified

21 FIBER PROPERTIES Specific strength versus specific modulus for different types of fibers

22 Glass Fibers Fiberglass refers to a group of products made from individual glass fibers combined into a variety of forms. Glass fibers can be divided into two major groups according to their geometry: continuous fibers used in yarns and textiles, and the discontinuous (short) fibers used as batts, blankets, or boards for insulation and filtration. Fiberglass can be formed into yarn much like wool or cotton, and woven into fabric which is sometimes used for draperies. Fiberglass textiles are commonly used as a reinforcement material for molded and laminated plastics. Fiberglass wool, a thick, fluffy material made from discontinuous fibers, is used for thermal insulation and sound absorption. It is commonly found in ship and submarine bulkheads and hulls; automobile engine compartments and body panel liners; in furnaces and air conditioning units; acoustical wall and ceiling panels; and architectural partitions.

23 Glass Fibers The basic raw materials for fiberglass products are a variety of natural minerals and manufactured chemicals. The major ingredients are silica sand, limestone, and soda ash. Other ingredients may include calcined alumina, borax, feldspar, nepheline syenite, magnesite, and kaolin clay, among others. Silica sand is used as the glass former, and soda ash and limestone help primarily to lower the melting temperature. Other ingredients are used to improve certain properties, such as borax for chemical resistance. Waste glass, also called cullet, is also used as a raw material.

24 Glass Fibers Fiberglass properties vary somewhat according to the type of glass used. However, glass in general has several well known properties that contribute to its great usefulness as a reinforcing agent: Tensile strength Chemical resistance Moisture resistance Thermal properties Electrical properties There are four main types of glass used in fiberglass: A glass C glass E glass S glass

25 Glass Fibers Due to the relatively inexpensive cost glass fibers are the most commonly used reinforcement There are a variety of types of glass, they are all compounds of silica with a variety of metallic oxides Designation Property or Characteristic Composition, % E, electrical low electrical conductivity 55 SiO 2, 11 Al 2 O 3, 6 B 2 O 3, 18 CaO, 5 MgO S, strength high strength 65 SiO 2, 25 Al 2 O 3, 10 MgO C, chemical high chemical durability M, modulus high stiffness A, alkali high alkali or soda lime glass D, dielectric low dielectric constant 65 SiO 2, 4 Al 2 O 3, 6 B 2 O 3, 14 CaO, 3 MgO, 9 K 2 O The most commonly used glass is E-glass due to its low cost

26 Glass Fibers Most widely used fiber Uses: piping, tanks, boats, sporting goods Advantages Low cost Corrosion resistance Low cost relative to other composites: Disadvantages Relatively low strength High elongation Moderate strength and weight Types: E-Glass - electrical, cheaper S-Glass - high strength

27 Glass Fibers Glass fibers produced by spinning liquid glass directly to fine fibers. Just as in the Griffith experiments, the strength is based on small diameter. Modulus ranges from GPa. Strength ranges from GPa Breaking strain from 2 to 5% Density ~ 2.5 gm/cm 3. E glass (electrical, borosilicate glass) is the cheapest and most common. R glass and S glass is more expensive but more corrosion resistant, for example and higher strength.

28 Carbon Fibers Carbon fibers have gained a lot of popularity in the last two decades due to the price reduction Carbon fiber composites are five times stronger than 1020 steel yet five times lighter. In comparison to 6061 aluminum, carbon fiber composites are seven times stronger and two times stiffer yet still 1.5 times lighter Initially used exclusively by the aerospace industry they are becoming more and more common in fields such as automotive, civil infrastructure, and paper production

29 Carbon Fibers

30 Carbon Fibers

31 Carbon Fibers 2 nd most widely used fiber Examples aerospace, sporting goods Advantages high stiffness and strength low density intermediate cost Properties: Standard modulus: GPa Intermediate modulus: GPa High modulus: GPa Diameter: 5-8 microns, smaller than human hair Fibers grouped into tows or yarns of 2-12k fibers

32 Carbon Fibers Modulus ranges from GPa (cf. Steel-210) Strength ranges from 2-6 GPa Breaking strain ranges from % Density ranges from g/cm 3 Highest cost compared to glass or aramid, but greatest range of properties. Internal structure consists of radially-aligned graphite platelets, which leads to some anisotropy in properties in the fibers. Both thermal and electrical conductivity are generally good (but then insulation required where metals might be in contact for carbon-fiber composite).

33 Carbon Fibers Types of carbon fiber vary in strength with processing Trade-off between strength and modulus Intermediate modulus PAN (Polyacrylonitrile) fiber precursor heated and stretched to align structure and remove non-carbon material High modulus made from petroleum pitch precursor at lower cost much lower strength

34 Carbon Fibers Carbon Fiber Production Carbon fiber is currently produced in relatively limited quantities mostly via two manufacturing processes: Based on pitch (coal tar and petroleum products) Based on Polyacrylonitrile (PAN) Current global capacity for pitch-based carbon fiber is estimated at about 3,500 metric tons per year. Global use for PAN-based carbon fiber is increasing rapidly, and total production capacity currently does not meet the demand. PAN-based carbon fiber is more expensive to produce, hence, limiting its use to high end applications, (used primarily by aerospace and sporting equipment industries)

35 Carbon Fibers Carbon Fiber Properties Pitch and PAN carbon fibers have properties that suit different applications. The most common carbon-fiber type is PAN, primarily for structural reinforcement because of its high tensile strength. Mesophase pitch fibers, on the other hand, offer designers a different profile. They are easily customized to meet specific applications. They often have a higher modulus, or stiffness than conventional PAN fibers, are intrinsically more pure electrochemically, and have higher ionic intercalation. Mesophase Pitch fibers also possess higher thermal and electrical conductivity, and different friction properties.

36 Carbon Fibers Global demand for high-strength, light-weight and durable fiber is growing; typical applications in: Portable power Rechargeable batteries and fuel cell electrodes Fiber reinforced plastics, FRP Energy production; windmill blades Building and construction materials: concrete and asphalt reinforcements, soil erosion barriers Electronics, composite materials for automotives & general transportation, Specialty and niche markets.

37 Fibers Others Boron High stiffness, very high cost Large diameter microns Good compressive strength Polyethylene - trade name: Spectra fiber Textile industry High strength Extremely light weight Low range of temperature usage

38 Fibers Others Ceramic Fibers (and matrices) Very high temperature applications (e.g. engine components) Silicon carbide fiber - in whisker form. Ceramic matrix so temperature resistance is not compromised Infrequent use

39 Fiber Material Properties Steel: density (Fe) = 7.87 cm 3 ; TS=0.380 GPa; Modulus=207 GPa Al: density=2.71 g/cm 3 ; TS=0.035 GPa; Modulus=69 GPa

40 Fibers-Aramid -Aramid fibers are also becoming more and more common -They have the highest level of specific strength of all the common fibers -They are commonly used when a degree of impact resistance is required such as in ballistic armour -The most common type of aramid is Kevlar china.com/product/weenpacbauyc/china-covert- Aramid-Bulletproof-Vest-Body-Armor-TAT-FJ-2-.html

41 Fibers-Aramid Kevlar and Aramid Fibers (Opaque Armor) Only the highest grade, waterproof Kevlar and aramid fibers are used. These fibers offer superior blast, fragmentation, explosive and small arms ballistic protection. All materials are tested in an independent laboratory and are custom fabricated according to TAC specifications.

42 Fiber Strength

43 FIBER PROPERTIES COMPARATIVE COST OF FIBER REINFORCEMENT Fiber Cost ($/lb) Boron 320 Silicon Carbide 100 Carbon 30 Alumina 30 Kevlar 20 E-Glass 3

44 Fiber Reinforced Composites CHARACTERISTICS OF FIBER REINFORCED COMPOSITES As can be seen from this plot, the strength of the composite increases as the fiber length increases (this is a chopped E-glassepoxy composite)

45 Fiber Reinforced Composites Some commonly used fibers for polymer matrix composites: Glass fibers Carbon fibers Aramid fibers Some commonly used fibers for metal matrix composites: Boron fibers Carbon fibers Oxide ceramic and non-oxide ceramic fibers

46 THE END

47 Any Questions