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COMPOSITE MATERIALS
BSECE 4-A
GROUP 5
ADAMS, ROWELL
CAYABYAB, JHED LANIEL
CORPUZ, JANMARC
DE PEDRO, RYAN
ELLE, JOHN CARLO
RIVERA, DAYLE JERICHO
What is Composite Materials?
• It is a material that made by
combining two or more materials
that usually have different
physical and chemical properties.
• When they are combined, they
can create a material that have
unique properties.
IMPORTANT ROLE OF COMPOSITES
THROUGHOUT HUMAN HISTORY
• PLYWOOD
• CONCRETE
• CARTONNAGE
• COB
• PAPIER-MACHE
PLYWOOD
• Gluing thin sheet of
wood together to create
a thicker and stronger
final product
CONCRETE
• Made up of a
filler(Aggregates like
stone, sand, etc.) and a
binder(Cement paste).
CARTONNAGE
• It was made of layers
of linen or papyrus
covered with plaster
with plaster.
10/24/2023
Sample Footer Text 6
COB
• Also called Mud Bricks
or Mud Walls.
• It is a mixture of Clay,
Sand and Straw.
PAPIER-MACHE
• consisting of paper pieces
or pulp, sometimes
reinforced with textiles,
bound with an adhesive,
such as glue, starch, or
wallpaper paste.
PROPERTIES OF COMPOSITES
• STRONG
• LIGHTWEIGHT
• CORROSION RESISTANCE
• LOW DENSITY
• LOW THERMAL CONDUCTIVITY
• LOW COEFFICIENT OF THERMAL EXPANSION
• SHOCK RESISTANCE
• FATIQUE AND CREEP RESISTANCE
Weight reduction
Design flexibility
Properties are superior from
constituents
Expensive material
Have limited shelf life
Cannot be easily recycled
Specialized manufacturing process
required
REINFORCEMENT
OR DISPERSED
PHASE
MATRIX
PHASE
•
•
SUBDIVISION
0RGANIC MATRIX COMPOSITES
METALLIC MATRIX COMPOSITES
CERAMIC MATRIX COMPOSITES
CARBON-CARBON MATRIX
COMPOSITES
•
•
Provide superior levels of strength and
stiffness to the composite.
Provide superior levels of strength and
stiffness to the composite.
Provide thermal and electrical conductivity,
controlled thermal expansion, and wear
resistance in addition to structural
properties.
SUBDIVISION
FIBER-REINFORCED
COMPOSITES
LAMINAR COMPOSITES
PARTICULATE COMPOSITES
COMPOSITES WITH
RESPECT TO
MATRIX CONSTITUENTS
Matrix phase refers to one
of the two main components
of the composite structure,
the other being the
reinforcement phase.
These two phases work
together to create a
composite material with
enhanced properties
compared to the individual
components. This two
constituents make
composites heterogeneous
at a microscopic scale but
statically homogeneous at
• Holds the fibers together
• Protects the fibers from environment
• Distributes the loads evenly between fibers so that
all fibers are subjected to same amount of strain
• Enhances transverse properties of a laminate
• Improves impact and fracture resistance of a
component
• Carry inter laminar shear
FUNCTIONS OF MATRIX
• Holds the fibers together
• Protects the fibers from environment
• Distributes the loads evenly between fibers so that
all fibers are subjected to same amount of strain
• Enhances transverse properties of a laminate
• Improves impact and fracture resistance of a
component
• Carry inter laminar shear
FUNCTIONS OF MATRIX
FUNCTIONS OF MATRIX
SHORT-BEAM
METHOD
INTERLAMINAR SHEAR
STRENGTH
FUNCTIONS OF MATRIX
RED-DASHED LINE IS
DUE TO COMPOSITE
ACTION
Subjected to tensile and
compressive stress
RED-DASHED LINE IS
DUE TO COMPOSITE
ACTION
Subjected to tensile and
compressive stress
In order for the combined action
to move into composite action the
top slab is forced to shorten, and
the bottom slab is forced to
lengthen. Transverse shear
transferred tensile stress from the
top section into the bottom one
which is one of the primary
functions of matrices, to
distribute loads or forces evenly
to the reinforcements.
• Reduced moisture absorption
• Low shrinkage
• Low coefficient of thermal expansion
• Strength at elevated temperature
• Low temperature capability
• Excellent chemical resistance
DESIRED PROPERTIES OF MATRIX
OMCs are generally assumed to include and be categorized
based on matrix material used which can be either a
polymer or a carbon; PMCs and CAMCs.
ORGANIC MATRIX COMPOSITES
POLYMER MATRIX COMPOSITES
PMCs are be classified based on the type of polymer
implemented. The two major classes of polymers used as
composite matrix materials are thermosets and
thermoplastics.
Maximum Service Temperature. The elastic and
strength properties of polymers decrease with increasing
temperature. A widely used measure of comparative
temperature resistance of polymers is the glass transition
temperature, Tg, which is the approximate measure of the
temperature at which a polymer transitions from a relatively
rigid material to a rubbery one.
E.g. Carbon fiber-reinforced polyimides have replaced
titanium in some aircraft gas turbine engine parts.
IMPORTANT CONSIDERATIONS IN RESIN SELECTION
Moisture Sensitivity. Resins tend to absorb water,
which causes dimensional changes and reduction of
strength, stiffness, and Tg. When the resins absorbed
enough moisture, they can resist higher temperatures,
resulting in varied glass transition temperatures. The rate of
absorption and desorption depends strongly on temperature.
The moisture sensitivity of resins varies widely, and some
are very resistant when cured. They tend to desorb moisture
at drier atmospheres.
IMPORTANT CONSIDERATIONS IN RESIN SELECTION
Most widely used matrix resin due to a curing process that
makes them rigid and cannot be reformed. They also tend to
be more resistant to corrosive environments and solvents.
They become cross linked during fabrication & do not
soften upon reheating. One example is rubber.
THERMOSETTING RESINS
THERMOPLASTIC RESINS
Thermoplastics, on the other hand, can be repeatedly
softened and re-formed by application of heat. They
soften upon heating and can be reshaped with heat and
pressure.
Thermoplastic can be synthesized by the process called
addition polymerization while thermosets are by
condensation polymerization.
Addition
Polymerization
Monomer alkene ethene
joined to form polyethene
polymer
Condensation
Polymerization
Epoxies are the workhorse materials for
airframe structures and other aerospace
applications. They produce composites
with excellent structural properties.
Epoxies tend to be rather brittle materials,
but toughened formulations with greatly
improved impact resistance are available.
The maximum service temperature is
affected by reduced elevated-temperature
structural properties resulting from water
absorption. A typical airframe limit is
about 120∘C (250∘F).
SOME THERMOSETS
Bismaleimide resins are used for
aerospace applications requiring higher
temperature capabilities than can be
achieved by epoxies. They are employed
for temperatures of up to about 200∘C
(390∘F).
Thermosetting polyimides are being used in applications at
temperatures as high as 250–290∘C (500–550∘F). However,
new resins have been developed with even higher
temperature limits.
Phenolic resins have good high-
temperature resistance and produce less
smoke and toxic
products than most resins when burned.
They are used in applications such as
aircraft interiors
and offshore oil platform structures, for
which fire resistance is a key design
requirement..
SOME
THERMOPLASTICS
Nylon, a crystalline
thermoplastic, tend to have
better solvent resistance and
are extensively used with
chopped E-glass fiber
reinforcements in countless
injection-molded parts.
Titanium, Aluminum, magnesium, and iron are
the popular matrix metals. Other metals used as
matrix materials, including copper, lead,
magnesium, cobalt, and silver. They are
characterized by their high strength, fracture
toughness, and stiffness in contrast with brittle
behavior of polymers and ceramics and have
higher resistances at higher temperatures in
corrosive environment than polymers.
MMCs
Only light metals are responsive,
with their low density proving an
advantage which are particularly
useful for aircraft applications.
Metal–matrix composites have
been developed for use in
temperature, conductivity, and
load conditions beyond the
capability of polymer–matrix
systems. For example, boron-
reinforced aluminum was used in
the Space Shuttle Orbiter, and
carbon-reinforced aluminum is
used in the Hubble Telescope.
Alumina-reinforced aluminum is
MMCs
SOME COMMON POLYMER MATRIX
MATERIALS
CERAMIC-MATRIX
COMPOSITE
CERAMIC
• hard, brittle, heat-resistant, and corrosion-resistant
• Common examples are earthenware, porcelain, and brick.
• Fracture toughness values for ceramic materials are low
and typically lie between 1 and 5 MPa.
Ceramic-Matrix Composite
• Ceramic-matrix composites (CMCs)—
particulates, fibers, or whiskers of one ceramic
material that have been embedded into a
matrix of another ceramic.
• Consisting of a ceramic matrix and one or
more additional property-modifying
components.
• Ceramic-matrix composite materials have
extended fracture toughness to between about
6 and 20 MPa √m
• Particulate
• Whisker
• Nano powder
• Oxide
• Non-oxide
• 𝑇𝑖𝑂2, 𝐴𝑙2𝑂3, 𝑆𝑖𝑂2 (Oxide)
• 𝑆𝑖𝐶, 𝑆𝑖𝑁, 𝑇𝑖𝐶, 𝑇𝑖𝑁, 𝑇𝑖𝐶𝑁 (Non-oxide)
In essence, this improvement in the fracture properties
results from interactions between advancing cracks and
dispersed phase particles. Crack initiation normally occurs
with the matrix phase, whereas crack propagation is
impeded or hindered by the particles, fibers, or whiskers.
Properties of CMCs
Applications of CMCs
CERAMIC COMPOSITE BRAKES: C/SIC
• High braking performance
• Low weight (2.4 g/cm")
• Low wear rate
• Operating temperatures 1,400°C
• First studied in 1990s, available in 2000s Mercedes
CL 55 AMG F1 Lim. Ed. (2000) Porsche 911 GT2
(2001) (PCCB)
• 50,000-70,000 CMC brake discs manufactured in
2006 SICOMT", BREMBO™', etc.
C/SiC rotor
Caliper w/pads
Applications of CMCs
AEROSPACE NOZZLE
• An F-16 Fighting Falcon F100 engine exhaust
nozzle with five A500 ceramic matrix
composite divergent seals, identified by the
yellow arrows. (Air Force photo)
CARBON-CARBON
COMPOSITE
CARBON-CARBON COMPOSITE
Properties of CCCs
• Excellent Thermal Shock Resistance
(Over 2000°C)
• Low Density ( 1830 Kg/m^3 )
• High Abrasion Resistance
• High Electrical Conductivity
• Non-Brittle Failure
Applications of CCCs
FIBER REINFORCED
COMPOSITES
FIBER REINFORCED COMPOSITES
• FIBER-REINFORCED COMPOSITES, OFTEN SIMPLY CALLED "COMPOSITES," ARE ADVANCED
MATERIALS THAT COMBINE TWO OR MORE DIFFERENT SUBSTANCES TO CREATE A FINAL
PRODUCT WITH UNIQUE AND IMPROVED PROPERTIES.
These materials consist of two main components:
MATRIX
• THE MATRIX IS A POLYMER, RESIN, OR OTHER BINDING MATERIAL THAT SURROUNDS AND HOLDS
THE REINFORCING FIBERS TOGETHER. IT TYPICALLY MAKES UP THE BULK OF THE COMPOSITE AND
PROVIDES THE OVERALL STRUCTURE AND SHAPE.
• COMMONN MATRIX MATERIALS
EPOXY POLYESTER THERMOPLASTIC
REINFORCING FIBERS
• HIGH-STRENGTH MATERIALS LIKE GLASS FIBERS, CARBON FIBERS, OR NATURAL FIBERS SUCH AS
BAMBOO OR HEMP ARE COMMONLY USED IN COMPOSITES. THESE FIBERS ARE ADDED TO THE
MATERIAL TO IMPROVE ITS STRENGTH, STIFFNESS, AND DURABILITY.
• COMMONN MATERIALS
GLASS FIBERS CARBON FIBERS NATURAL FIBERS
GLASS FIBER REINFORCED EPOXY
CARBON FIBER REINFORCED POLYESTER
NATURAL FIBER REINFORCED THERMOPLASTIC
GENERAL ADVANTAGES OF FRCS
DESIGN FREEDOM
DURABILITY
LIGHTWEIGHT
HIGH STRENGTH
DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS
WITHIN MATERIALS
• DISCONTINUOUS AND RANDOMLY ORIENTED FIBERS: SHORT FIBERS RANDOMLY DISTRIBUTED WITHIN A
MATERIAL, RESULTING IN ISOTROPIC PROPERTIES.
DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS
WITHIN MATERIALS
• DISCONTINUOUS AND ALIGNED FIBERS: SHORT FIBERS INTENTIONALLY ORIENTED IN A SPECIFIC DIRECTION
WITHIN A MATERIAL, POTENTIALLY RESULTING IN ANISOTROPIC PROPERTIES.
DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS
WITHIN MATERIALS
• CONTINUOUS AND ALIGNED FIBERS: LONG, UNBROKEN FIBERS INTENTIONALLY ORIENTED IN A SPECIFIC
DIRECTION WITHIN A MATERIAL, OFTEN RESULTING IN STRONG AND STIFF PROPERTIES ALONG THE
ALIGNMENT DIRECTION.
DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS
WITHIN MATERIALS
• FABRIC: A TEXTILE MATERIAL CREATED BY WEAVING OR KNITTING FIBERS TOGETHER, WHICH CAN BE MADE
FROM VARIOUS TYPES OF FIBERS AND HAS DIVERSE PROPERTIES DEPENDING ON ITS CONSTRUCTION.
LAMINAR
COMPOSITES
LAMINAR COMPOSITES
• LAMINAR COMPOSITE IS A TWO-DIMENSIONAL STRUCTURE MADE OF HIGH-STRENGTH SHEETS OR PANELS,
LIKE WOOD AND FIBER-REINFORCED PLASTICS, STACKED AND CEMENTED TOGETHER TO VARY THEIR
ORIENTATION.
COMPONENTS OF LAMINAR COMPOSITES
• LAYERS
• MATRIX MATERIAL
• REINFORCEMENT MATERIAL
• ORIENTATION
• LAYER THICKNESS AND SEQUENCE
• BONDING
COMPONENTS OF LAMINAR COMPOSITES
• LAYERS- LAMINAR COMPOSITES CONSIST OF TWO OR MORE LAYERS STACKED ON TOP OF
EACH OTHER.
• MATRIX MATERIAL- ONE OF THE LAYERS SERVES AS A MATRIX MATERIAL, OFTEN MADE OF A
POLYMER RESIN OR ANOTHER TYPE OF ADHESIVE SUBSTANCE.
• REINFORCEMENT MATERIAL- THE OTHER LAYERS, KNOWN AS REINFORCEMENT MATERIALS,
ARE TYPICALLY MADE OF FIBERS SUCH AS CARBON AND GLASS.
• ORIENTATION- THE ORIENTATION AND ARRANGEMENT OF THE REINFORCEMENT FIBERS
WITHIN EACH LAYER CAN BE CUSTOMIZED TO ACHIEVE SPECIFIC MECHANICAL PROPERTIES.
• LAYER THICKNESS AND SEQUENCE- THE THICKNESS OF EACH LAYER AND THE SEQUENCE IN
WHICH THEY ARE STACKED CAN BE ADJUSTED TO OPTIMIZE THE COMPOSITE'S PROPERTIES.
• BONDING- THE LAYERS ARE BONDED TOGETHER THROUGH PROCESSES SUCH AS CURING,
HEATING, OR PRESSURE APPLICATION, ENSURING A STRONG AND DURABLE CONNECTION
BETWEEN THEM.
ADVANTAGES OF LAMINAR COMPOSITES
HIGH
STRENGTH
LIGHT WEIGHT
DURABILITY
APPLICATIONS
AEROSPACE INDUSTRY
• LAMINAR COMPOSITES USED IN AIRCRAFT STRUCTURES TO REDUCE WEIGHT AND IMPROVE
FUEL EFFICIENCY.
• EXAMPLES: CARBON-FIBER COMPOSITES IN AIRCRAFT WINGS AND FUSELAGE.
APPLICATIONS
AUTOMOTIVE INDUSTRY
• LAMINAR COMPOSITES EMPLOYED IN VEHICLE COMPONENTS TO ENHANCE STRENGTH AND
REDUCE WEIGHT.
• EXAMPLES: CARBON-FIBER REINFORCED PARTS IN SPORTS CARS.
PARTICULATE
COMPOSITES
PARTICULATE COMPOSITES
• PARTICULATE COMPOSITES ARE COMPOSITE MATERIALS MADE BY COMBINING A MATRIX
MATERIAL WITH SMALL PARTICLES OR FILLER MATERIALS TO ENHANCE SPECIFIC PROPERTIES OR
ACHIEVE DESIRED CHARACTERISTICS.
• COMPOSED OF PARTICLES DISTRIBUTED OR EMBEDDED IN A MATRIX BODY. THE PARTICLES MAY
BE FLAKES OR IN POWDER FORM. CONCRETE AND WOOD PARTICLE BOARDS ARE EXAMPLES
OF THIS CATEGORY.
WOOD CONCRETE
KEY
ELEMENTS OF
PARTICULATE
COMPOSITES
Matrix Material
Dispersed Particles
• This is the primary substance that surrounds and
holds the particles together.
• These are solid particles, often of a different
material than the matrix, which are distributed
uniformly within the matrix.
THE COMBINATION OF THE MATRIX MATERIAL AND THE
DISPERSED PARTICLES IN A PARTICULATE COMPOSITE LEADS
TO SEVERAL ADVANTAGEOUS PROPERTIES
ENHANCE STRENGTH
IMPROVED HARDNESS
TAILORED PROPERTIES
REDUCED WEIGHT
TYPES OF PARTICULATE COMPOSITES
Metal Matrix
Composites (MMCs)
Ceramic Matrix
Composites (CMCs)
Polymer Matrix
Composites (PMCs)
APPLICATIONS
AEROSPACE
• LIGHTWEIGHT, HIGH-STRENGTH COMPOSITES USED IN AIRCRAFT STRUCTURES.
• IMPROVED FUEL EFFICIENCY AND PERFORMANCE.
AUTOMOTIVE
• ENHANCING FUEL EFFICIENCY BY REDUCING VEHICLE WEIGHT.
• ENHANCED CRASH SAFETY THROUGH HIGH-STRENGTH COMPOSITES IN CAR BODIES.
CONSTRUCTION
• REINFORCED CONCRETE WITH PARTICULATE COMPOSITES FOR ADDED STRENGTH.
• REDUCED MAINTENANCE COSTS IN HARSH ENVIRONMENTS.
FABRICATION METHODS
OF COMPOSITES
BY: REY IAN A. IGTOS
HAND LAYUP
• THIS IS A MANUAL
PROCESS WHERE LAYERS
OF REINFORCEMENT (SUCH
AS FIBERGLASS, CARBON
FIBER, OR FABRIC) ARE
PLACED IN A MOLD, AND
RESIN IS APPLIED BY HAND.
Hand Layup Process :
➢Ensure the mold is clean and coated
with a release agent .
➢Apply a thin layer of resin onto the
prepared mold's surface.
➢Place the cut reinforcing material onto
the wet resin.
➢Use roller to press out any air bubbles
➢Curing
MATCHED-DIE MOLDING
• ALSO KNOWN AS COMPRESSION MOLDING
• INVOLVES USING A SET OF MATCHED METAL MOLDS TO
PRODUCED HIGH QUALITY COMPOSITE PARTS.
Matched Die Molding Process :
➢Prepare the molds
➢Cut the reinforce materials
➢Layer the reinforce Materials
➢Compression
➢Curing
➢Cooling
INJECTION MOLDING
• IS A MANUFACTURING PROCESS USED TO PRODUCE A WIDE
VARIETY OF PLASTIC PARTS AND PRODUCTS.
• IT INVOLVES INJECTING MOLTEN PLASTIC MATERIAL INTO A
MOLD CAVITY UNDER HIGH PRESSURE AND THEN COOLING
AND SOLIDIFYING IT TO FORM THE DESIRED SHAPE.
Injection Molding Process :
➢Prepare the mold
➢Injection of molten composite materials
➢Cooling and Solidification
➢Demold
RESIN TRANSFORM MOLDING
(RTM)
•IS AN INTERMEDIATE VOLUME MOLDING PROCESS
FOR PRODUCING COMPOSITES.
•IN RTM, RESIN IS INJECTED UNDER PRESSURE INTO A
MOLD CAVITY
Resin Transform Molding (RTM)Process :
➢ Prepare the mold.
➢ Lay down reinforce fibers
➢ Vacuum Application
➢ Resin Injection
➢ Curing
FILAMENT WINDING
• IS A COMPOSITE FABRICATION METHOD USED TO
CREATE CYLINDRICAL OR TUBULAR COMPOSITE
STRUCTURES, SUCH AS PIPES, PRESSURE VESSELS, AND
ROCKET CASINGS.
• THIS PROCESS INVOLVES WINDING CONTINUOUS FIBERS
(FILAMENTS) ONTO A ROTATING MANDREL OR MOLD.
Filament Winding Process :
➢Prepare the Mandrel.
➢Set up the filament winding machine.
➢Resin application.
➢Winding Patterns.
➢Curing .
➢Cooling.
PULTRUSION
• IS A COMPOSITE FABRICATION METHOD USED TO PRODUCE
CONTINUOUS PROFILES WITH A CONSISTENT CROSS-SECTIONAL
SHAPE.
• IT IS USED TO CREATE COMPOSITE MATERIALS LIKE FIBERGLASS-
REINFORCED POLYMER (FRP) AND CARBON FIBER-REINFORCED
POLYMER (CFRP) PROFILES, RODS, AND TUBES.
Pultrusion Process :
➢ Prepare Reinforcing Fibers.
➢ Impregnated with Resin.
➢ Die and Heating section.
➢ Curing .
➢ Pulling system.
➢ Cooling.
➢ Cutoff.
PREPREG
•SHORT FOR “PRE-IMPREGNATED,”
•IT CONSISTS OF REINFORCING FIBERS (SUCH AS
CARBON FIBER, FIBERGLASS, OR ARAMID) THAT ARE
ALREADY IMPREGNATED OR “PRE-IMPREGNATED”
WITH A PRECISE AMOUNT OF RESIN.
Composite
Failure
Jhed Laniel L. Cayabyab
Shock, impact, or repeated
cyclic stresses can cause
the laminate to separate at
the interface between two
layers, a condition known
as delamination.
Individual fibres can
separate from the matrix
e.g. fibre pull-out.
Failure of a brittle ceramic matrix composite
occurred when the carbon-carbon
composite tile on the leading edge of the
wing of the Space Shuttle Columbia
fractured when impacted during take-off
Titan, was a submersible that imploded on
18 June 2023 while transporting tourists to
visit the wreckage of Titanic.
Titan submersible was constructed using
titanium alloy for the hemispherical domes
at each end of the vessel, and carbon fibre
reinforced plastic (CFRP) for the hull.
Titan Submersible
Implosion
Composite
Applications
Jhed Laniel L. Cayabyab
Aerospace
Carbon fiber is the most
widely used composite
fiber in aerospace
applications.
Aramid fibers, on the
other hand, are widely
used for constructing
leading and trailing
edge wing components
and very stiff, very light
bulkhead, fuel tanks and
floor
Space Shuttle
• Aluminum and Magnesium
metallic composites are used
for their light weight
• Thermal Protection
System(TPS)
• Reinforced carbon-carbon
(RCC), used in the nose cap,
the chin area between the
nose cap and nose landing
geardoors( 1,260 °c {2,300 °F))
AUTOMOBILE
• Engines bodies
• Piston
• Cylinder
• connecting rod
• crankshafts
• bearing materials
• brake discs
CONSTRUCTION
cost-effective and can withstand substantial
compressive forces without breaking.
Concrete
CONSTRUCTION
A laminar composite
Plywood
used in Bridge structures
Fiber-Reinforced
Polymers
Medical Application
• Orthopedic applications: bone
fixation plates, hip joint replacement,
bone cement, and bone grafts
• External Prosthetics
Medical Application
• Composite materials are used
in clinical practice to restore
anterior and posterior teeth.
Other Applications
Electronics Sports equipments
Marine
Military applications
THANKS FOR
LISTENING

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Composites.pdf

  • 1. COMPOSITE MATERIALS BSECE 4-A GROUP 5 ADAMS, ROWELL CAYABYAB, JHED LANIEL CORPUZ, JANMARC DE PEDRO, RYAN ELLE, JOHN CARLO RIVERA, DAYLE JERICHO
  • 2. What is Composite Materials? • It is a material that made by combining two or more materials that usually have different physical and chemical properties. • When they are combined, they can create a material that have unique properties.
  • 3. IMPORTANT ROLE OF COMPOSITES THROUGHOUT HUMAN HISTORY • PLYWOOD • CONCRETE • CARTONNAGE • COB • PAPIER-MACHE
  • 4. PLYWOOD • Gluing thin sheet of wood together to create a thicker and stronger final product
  • 5. CONCRETE • Made up of a filler(Aggregates like stone, sand, etc.) and a binder(Cement paste).
  • 6. CARTONNAGE • It was made of layers of linen or papyrus covered with plaster with plaster. 10/24/2023 Sample Footer Text 6
  • 7. COB • Also called Mud Bricks or Mud Walls. • It is a mixture of Clay, Sand and Straw.
  • 8. PAPIER-MACHE • consisting of paper pieces or pulp, sometimes reinforced with textiles, bound with an adhesive, such as glue, starch, or wallpaper paste.
  • 9. PROPERTIES OF COMPOSITES • STRONG • LIGHTWEIGHT • CORROSION RESISTANCE • LOW DENSITY • LOW THERMAL CONDUCTIVITY • LOW COEFFICIENT OF THERMAL EXPANSION • SHOCK RESISTANCE • FATIQUE AND CREEP RESISTANCE
  • 10.
  • 11. Weight reduction Design flexibility Properties are superior from constituents
  • 12.
  • 13. Expensive material Have limited shelf life Cannot be easily recycled Specialized manufacturing process required
  • 16. SUBDIVISION 0RGANIC MATRIX COMPOSITES METALLIC MATRIX COMPOSITES CERAMIC MATRIX COMPOSITES CARBON-CARBON MATRIX COMPOSITES
  • 18. Provide superior levels of strength and stiffness to the composite. Provide superior levels of strength and stiffness to the composite. Provide thermal and electrical conductivity, controlled thermal expansion, and wear resistance in addition to structural properties.
  • 21. Matrix phase refers to one of the two main components of the composite structure, the other being the reinforcement phase. These two phases work together to create a composite material with enhanced properties compared to the individual components. This two constituents make composites heterogeneous at a microscopic scale but statically homogeneous at
  • 22. • Holds the fibers together • Protects the fibers from environment • Distributes the loads evenly between fibers so that all fibers are subjected to same amount of strain • Enhances transverse properties of a laminate • Improves impact and fracture resistance of a component • Carry inter laminar shear FUNCTIONS OF MATRIX
  • 23. • Holds the fibers together • Protects the fibers from environment • Distributes the loads evenly between fibers so that all fibers are subjected to same amount of strain • Enhances transverse properties of a laminate • Improves impact and fracture resistance of a component • Carry inter laminar shear FUNCTIONS OF MATRIX
  • 25. FUNCTIONS OF MATRIX RED-DASHED LINE IS DUE TO COMPOSITE ACTION Subjected to tensile and compressive stress
  • 26. RED-DASHED LINE IS DUE TO COMPOSITE ACTION Subjected to tensile and compressive stress In order for the combined action to move into composite action the top slab is forced to shorten, and the bottom slab is forced to lengthen. Transverse shear transferred tensile stress from the top section into the bottom one which is one of the primary functions of matrices, to distribute loads or forces evenly to the reinforcements.
  • 27. • Reduced moisture absorption • Low shrinkage • Low coefficient of thermal expansion • Strength at elevated temperature • Low temperature capability • Excellent chemical resistance DESIRED PROPERTIES OF MATRIX
  • 28. OMCs are generally assumed to include and be categorized based on matrix material used which can be either a polymer or a carbon; PMCs and CAMCs. ORGANIC MATRIX COMPOSITES POLYMER MATRIX COMPOSITES PMCs are be classified based on the type of polymer implemented. The two major classes of polymers used as composite matrix materials are thermosets and thermoplastics.
  • 29. Maximum Service Temperature. The elastic and strength properties of polymers decrease with increasing temperature. A widely used measure of comparative temperature resistance of polymers is the glass transition temperature, Tg, which is the approximate measure of the temperature at which a polymer transitions from a relatively rigid material to a rubbery one. E.g. Carbon fiber-reinforced polyimides have replaced titanium in some aircraft gas turbine engine parts. IMPORTANT CONSIDERATIONS IN RESIN SELECTION
  • 30. Moisture Sensitivity. Resins tend to absorb water, which causes dimensional changes and reduction of strength, stiffness, and Tg. When the resins absorbed enough moisture, they can resist higher temperatures, resulting in varied glass transition temperatures. The rate of absorption and desorption depends strongly on temperature. The moisture sensitivity of resins varies widely, and some are very resistant when cured. They tend to desorb moisture at drier atmospheres. IMPORTANT CONSIDERATIONS IN RESIN SELECTION
  • 31. Most widely used matrix resin due to a curing process that makes them rigid and cannot be reformed. They also tend to be more resistant to corrosive environments and solvents. They become cross linked during fabrication & do not soften upon reheating. One example is rubber. THERMOSETTING RESINS THERMOPLASTIC RESINS Thermoplastics, on the other hand, can be repeatedly softened and re-formed by application of heat. They soften upon heating and can be reshaped with heat and pressure.
  • 32.
  • 33. Thermoplastic can be synthesized by the process called addition polymerization while thermosets are by condensation polymerization.
  • 36. Epoxies are the workhorse materials for airframe structures and other aerospace applications. They produce composites with excellent structural properties. Epoxies tend to be rather brittle materials, but toughened formulations with greatly improved impact resistance are available. The maximum service temperature is affected by reduced elevated-temperature structural properties resulting from water absorption. A typical airframe limit is about 120∘C (250∘F). SOME THERMOSETS
  • 37. Bismaleimide resins are used for aerospace applications requiring higher temperature capabilities than can be achieved by epoxies. They are employed for temperatures of up to about 200∘C (390∘F).
  • 38. Thermosetting polyimides are being used in applications at temperatures as high as 250–290∘C (500–550∘F). However, new resins have been developed with even higher temperature limits.
  • 39. Phenolic resins have good high- temperature resistance and produce less smoke and toxic products than most resins when burned. They are used in applications such as aircraft interiors and offshore oil platform structures, for which fire resistance is a key design requirement..
  • 40. SOME THERMOPLASTICS Nylon, a crystalline thermoplastic, tend to have better solvent resistance and are extensively used with chopped E-glass fiber reinforcements in countless injection-molded parts.
  • 41. Titanium, Aluminum, magnesium, and iron are the popular matrix metals. Other metals used as matrix materials, including copper, lead, magnesium, cobalt, and silver. They are characterized by their high strength, fracture toughness, and stiffness in contrast with brittle behavior of polymers and ceramics and have higher resistances at higher temperatures in corrosive environment than polymers. MMCs
  • 42. Only light metals are responsive, with their low density proving an advantage which are particularly useful for aircraft applications. Metal–matrix composites have been developed for use in temperature, conductivity, and load conditions beyond the capability of polymer–matrix systems. For example, boron- reinforced aluminum was used in the Space Shuttle Orbiter, and carbon-reinforced aluminum is used in the Hubble Telescope. Alumina-reinforced aluminum is MMCs
  • 43. SOME COMMON POLYMER MATRIX MATERIALS
  • 44.
  • 46. CERAMIC • hard, brittle, heat-resistant, and corrosion-resistant • Common examples are earthenware, porcelain, and brick. • Fracture toughness values for ceramic materials are low and typically lie between 1 and 5 MPa.
  • 47. Ceramic-Matrix Composite • Ceramic-matrix composites (CMCs)— particulates, fibers, or whiskers of one ceramic material that have been embedded into a matrix of another ceramic. • Consisting of a ceramic matrix and one or more additional property-modifying components. • Ceramic-matrix composite materials have extended fracture toughness to between about 6 and 20 MPa √m
  • 48. • Particulate • Whisker • Nano powder • Oxide • Non-oxide • 𝑇𝑖𝑂2, 𝐴𝑙2𝑂3, 𝑆𝑖𝑂2 (Oxide) • 𝑆𝑖𝐶, 𝑆𝑖𝑁, 𝑇𝑖𝐶, 𝑇𝑖𝑁, 𝑇𝑖𝐶𝑁 (Non-oxide)
  • 49.
  • 50. In essence, this improvement in the fracture properties results from interactions between advancing cracks and dispersed phase particles. Crack initiation normally occurs with the matrix phase, whereas crack propagation is impeded or hindered by the particles, fibers, or whiskers.
  • 51.
  • 53. Applications of CMCs CERAMIC COMPOSITE BRAKES: C/SIC • High braking performance • Low weight (2.4 g/cm") • Low wear rate • Operating temperatures 1,400°C • First studied in 1990s, available in 2000s Mercedes CL 55 AMG F1 Lim. Ed. (2000) Porsche 911 GT2 (2001) (PCCB) • 50,000-70,000 CMC brake discs manufactured in 2006 SICOMT", BREMBO™', etc. C/SiC rotor Caliper w/pads
  • 54. Applications of CMCs AEROSPACE NOZZLE • An F-16 Fighting Falcon F100 engine exhaust nozzle with five A500 ceramic matrix composite divergent seals, identified by the yellow arrows. (Air Force photo)
  • 57.
  • 58. Properties of CCCs • Excellent Thermal Shock Resistance (Over 2000°C) • Low Density ( 1830 Kg/m^3 ) • High Abrasion Resistance • High Electrical Conductivity • Non-Brittle Failure
  • 61. FIBER REINFORCED COMPOSITES • FIBER-REINFORCED COMPOSITES, OFTEN SIMPLY CALLED "COMPOSITES," ARE ADVANCED MATERIALS THAT COMBINE TWO OR MORE DIFFERENT SUBSTANCES TO CREATE A FINAL PRODUCT WITH UNIQUE AND IMPROVED PROPERTIES. These materials consist of two main components:
  • 62. MATRIX • THE MATRIX IS A POLYMER, RESIN, OR OTHER BINDING MATERIAL THAT SURROUNDS AND HOLDS THE REINFORCING FIBERS TOGETHER. IT TYPICALLY MAKES UP THE BULK OF THE COMPOSITE AND PROVIDES THE OVERALL STRUCTURE AND SHAPE. • COMMONN MATRIX MATERIALS EPOXY POLYESTER THERMOPLASTIC
  • 63. REINFORCING FIBERS • HIGH-STRENGTH MATERIALS LIKE GLASS FIBERS, CARBON FIBERS, OR NATURAL FIBERS SUCH AS BAMBOO OR HEMP ARE COMMONLY USED IN COMPOSITES. THESE FIBERS ARE ADDED TO THE MATERIAL TO IMPROVE ITS STRENGTH, STIFFNESS, AND DURABILITY. • COMMONN MATERIALS GLASS FIBERS CARBON FIBERS NATURAL FIBERS
  • 64. GLASS FIBER REINFORCED EPOXY CARBON FIBER REINFORCED POLYESTER NATURAL FIBER REINFORCED THERMOPLASTIC
  • 65. GENERAL ADVANTAGES OF FRCS DESIGN FREEDOM DURABILITY LIGHTWEIGHT HIGH STRENGTH
  • 66. DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS WITHIN MATERIALS • DISCONTINUOUS AND RANDOMLY ORIENTED FIBERS: SHORT FIBERS RANDOMLY DISTRIBUTED WITHIN A MATERIAL, RESULTING IN ISOTROPIC PROPERTIES.
  • 67. DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS WITHIN MATERIALS • DISCONTINUOUS AND ALIGNED FIBERS: SHORT FIBERS INTENTIONALLY ORIENTED IN A SPECIFIC DIRECTION WITHIN A MATERIAL, POTENTIALLY RESULTING IN ANISOTROPIC PROPERTIES.
  • 68. DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS WITHIN MATERIALS • CONTINUOUS AND ALIGNED FIBERS: LONG, UNBROKEN FIBERS INTENTIONALLY ORIENTED IN A SPECIFIC DIRECTION WITHIN A MATERIAL, OFTEN RESULTING IN STRONG AND STIFF PROPERTIES ALONG THE ALIGNMENT DIRECTION.
  • 69. DIFFERENT ARRANGEMENTS AND TYPES OF FIBERS WITHIN MATERIALS • FABRIC: A TEXTILE MATERIAL CREATED BY WEAVING OR KNITTING FIBERS TOGETHER, WHICH CAN BE MADE FROM VARIOUS TYPES OF FIBERS AND HAS DIVERSE PROPERTIES DEPENDING ON ITS CONSTRUCTION.
  • 71. LAMINAR COMPOSITES • LAMINAR COMPOSITE IS A TWO-DIMENSIONAL STRUCTURE MADE OF HIGH-STRENGTH SHEETS OR PANELS, LIKE WOOD AND FIBER-REINFORCED PLASTICS, STACKED AND CEMENTED TOGETHER TO VARY THEIR ORIENTATION.
  • 72. COMPONENTS OF LAMINAR COMPOSITES • LAYERS • MATRIX MATERIAL • REINFORCEMENT MATERIAL • ORIENTATION • LAYER THICKNESS AND SEQUENCE • BONDING
  • 73. COMPONENTS OF LAMINAR COMPOSITES • LAYERS- LAMINAR COMPOSITES CONSIST OF TWO OR MORE LAYERS STACKED ON TOP OF EACH OTHER. • MATRIX MATERIAL- ONE OF THE LAYERS SERVES AS A MATRIX MATERIAL, OFTEN MADE OF A POLYMER RESIN OR ANOTHER TYPE OF ADHESIVE SUBSTANCE. • REINFORCEMENT MATERIAL- THE OTHER LAYERS, KNOWN AS REINFORCEMENT MATERIALS, ARE TYPICALLY MADE OF FIBERS SUCH AS CARBON AND GLASS. • ORIENTATION- THE ORIENTATION AND ARRANGEMENT OF THE REINFORCEMENT FIBERS WITHIN EACH LAYER CAN BE CUSTOMIZED TO ACHIEVE SPECIFIC MECHANICAL PROPERTIES. • LAYER THICKNESS AND SEQUENCE- THE THICKNESS OF EACH LAYER AND THE SEQUENCE IN WHICH THEY ARE STACKED CAN BE ADJUSTED TO OPTIMIZE THE COMPOSITE'S PROPERTIES. • BONDING- THE LAYERS ARE BONDED TOGETHER THROUGH PROCESSES SUCH AS CURING, HEATING, OR PRESSURE APPLICATION, ENSURING A STRONG AND DURABLE CONNECTION BETWEEN THEM.
  • 74. ADVANTAGES OF LAMINAR COMPOSITES HIGH STRENGTH LIGHT WEIGHT DURABILITY
  • 75. APPLICATIONS AEROSPACE INDUSTRY • LAMINAR COMPOSITES USED IN AIRCRAFT STRUCTURES TO REDUCE WEIGHT AND IMPROVE FUEL EFFICIENCY. • EXAMPLES: CARBON-FIBER COMPOSITES IN AIRCRAFT WINGS AND FUSELAGE.
  • 76. APPLICATIONS AUTOMOTIVE INDUSTRY • LAMINAR COMPOSITES EMPLOYED IN VEHICLE COMPONENTS TO ENHANCE STRENGTH AND REDUCE WEIGHT. • EXAMPLES: CARBON-FIBER REINFORCED PARTS IN SPORTS CARS.
  • 78. PARTICULATE COMPOSITES • PARTICULATE COMPOSITES ARE COMPOSITE MATERIALS MADE BY COMBINING A MATRIX MATERIAL WITH SMALL PARTICLES OR FILLER MATERIALS TO ENHANCE SPECIFIC PROPERTIES OR ACHIEVE DESIRED CHARACTERISTICS. • COMPOSED OF PARTICLES DISTRIBUTED OR EMBEDDED IN A MATRIX BODY. THE PARTICLES MAY BE FLAKES OR IN POWDER FORM. CONCRETE AND WOOD PARTICLE BOARDS ARE EXAMPLES OF THIS CATEGORY. WOOD CONCRETE
  • 79. KEY ELEMENTS OF PARTICULATE COMPOSITES Matrix Material Dispersed Particles • This is the primary substance that surrounds and holds the particles together. • These are solid particles, often of a different material than the matrix, which are distributed uniformly within the matrix.
  • 80. THE COMBINATION OF THE MATRIX MATERIAL AND THE DISPERSED PARTICLES IN A PARTICULATE COMPOSITE LEADS TO SEVERAL ADVANTAGEOUS PROPERTIES ENHANCE STRENGTH IMPROVED HARDNESS TAILORED PROPERTIES REDUCED WEIGHT
  • 81. TYPES OF PARTICULATE COMPOSITES Metal Matrix Composites (MMCs) Ceramic Matrix Composites (CMCs) Polymer Matrix Composites (PMCs)
  • 82. APPLICATIONS AEROSPACE • LIGHTWEIGHT, HIGH-STRENGTH COMPOSITES USED IN AIRCRAFT STRUCTURES. • IMPROVED FUEL EFFICIENCY AND PERFORMANCE. AUTOMOTIVE • ENHANCING FUEL EFFICIENCY BY REDUCING VEHICLE WEIGHT. • ENHANCED CRASH SAFETY THROUGH HIGH-STRENGTH COMPOSITES IN CAR BODIES. CONSTRUCTION • REINFORCED CONCRETE WITH PARTICULATE COMPOSITES FOR ADDED STRENGTH. • REDUCED MAINTENANCE COSTS IN HARSH ENVIRONMENTS.
  • 84. HAND LAYUP • THIS IS A MANUAL PROCESS WHERE LAYERS OF REINFORCEMENT (SUCH AS FIBERGLASS, CARBON FIBER, OR FABRIC) ARE PLACED IN A MOLD, AND RESIN IS APPLIED BY HAND.
  • 85. Hand Layup Process : ➢Ensure the mold is clean and coated with a release agent . ➢Apply a thin layer of resin onto the prepared mold's surface. ➢Place the cut reinforcing material onto the wet resin. ➢Use roller to press out any air bubbles ➢Curing
  • 86. MATCHED-DIE MOLDING • ALSO KNOWN AS COMPRESSION MOLDING • INVOLVES USING A SET OF MATCHED METAL MOLDS TO PRODUCED HIGH QUALITY COMPOSITE PARTS.
  • 87. Matched Die Molding Process : ➢Prepare the molds ➢Cut the reinforce materials ➢Layer the reinforce Materials ➢Compression ➢Curing ➢Cooling
  • 88.
  • 89.
  • 90. INJECTION MOLDING • IS A MANUFACTURING PROCESS USED TO PRODUCE A WIDE VARIETY OF PLASTIC PARTS AND PRODUCTS. • IT INVOLVES INJECTING MOLTEN PLASTIC MATERIAL INTO A MOLD CAVITY UNDER HIGH PRESSURE AND THEN COOLING AND SOLIDIFYING IT TO FORM THE DESIRED SHAPE.
  • 91. Injection Molding Process : ➢Prepare the mold ➢Injection of molten composite materials ➢Cooling and Solidification ➢Demold
  • 92.
  • 93.
  • 94. RESIN TRANSFORM MOLDING (RTM) •IS AN INTERMEDIATE VOLUME MOLDING PROCESS FOR PRODUCING COMPOSITES. •IN RTM, RESIN IS INJECTED UNDER PRESSURE INTO A MOLD CAVITY
  • 95. Resin Transform Molding (RTM)Process : ➢ Prepare the mold. ➢ Lay down reinforce fibers ➢ Vacuum Application ➢ Resin Injection ➢ Curing
  • 96.
  • 97. FILAMENT WINDING • IS A COMPOSITE FABRICATION METHOD USED TO CREATE CYLINDRICAL OR TUBULAR COMPOSITE STRUCTURES, SUCH AS PIPES, PRESSURE VESSELS, AND ROCKET CASINGS. • THIS PROCESS INVOLVES WINDING CONTINUOUS FIBERS (FILAMENTS) ONTO A ROTATING MANDREL OR MOLD.
  • 98. Filament Winding Process : ➢Prepare the Mandrel. ➢Set up the filament winding machine. ➢Resin application. ➢Winding Patterns. ➢Curing . ➢Cooling.
  • 99.
  • 100.
  • 101. PULTRUSION • IS A COMPOSITE FABRICATION METHOD USED TO PRODUCE CONTINUOUS PROFILES WITH A CONSISTENT CROSS-SECTIONAL SHAPE. • IT IS USED TO CREATE COMPOSITE MATERIALS LIKE FIBERGLASS- REINFORCED POLYMER (FRP) AND CARBON FIBER-REINFORCED POLYMER (CFRP) PROFILES, RODS, AND TUBES.
  • 102. Pultrusion Process : ➢ Prepare Reinforcing Fibers. ➢ Impregnated with Resin. ➢ Die and Heating section. ➢ Curing . ➢ Pulling system. ➢ Cooling. ➢ Cutoff.
  • 103.
  • 104. PREPREG •SHORT FOR “PRE-IMPREGNATED,” •IT CONSISTS OF REINFORCING FIBERS (SUCH AS CARBON FIBER, FIBERGLASS, OR ARAMID) THAT ARE ALREADY IMPREGNATED OR “PRE-IMPREGNATED” WITH A PRECISE AMOUNT OF RESIN.
  • 105.
  • 106.
  • 107.
  • 109. Shock, impact, or repeated cyclic stresses can cause the laminate to separate at the interface between two layers, a condition known as delamination. Individual fibres can separate from the matrix e.g. fibre pull-out.
  • 110. Failure of a brittle ceramic matrix composite occurred when the carbon-carbon composite tile on the leading edge of the wing of the Space Shuttle Columbia fractured when impacted during take-off
  • 111. Titan, was a submersible that imploded on 18 June 2023 while transporting tourists to visit the wreckage of Titanic. Titan submersible was constructed using titanium alloy for the hemispherical domes at each end of the vessel, and carbon fibre reinforced plastic (CFRP) for the hull. Titan Submersible Implosion
  • 113. Aerospace Carbon fiber is the most widely used composite fiber in aerospace applications. Aramid fibers, on the other hand, are widely used for constructing leading and trailing edge wing components and very stiff, very light bulkhead, fuel tanks and floor
  • 114. Space Shuttle • Aluminum and Magnesium metallic composites are used for their light weight • Thermal Protection System(TPS) • Reinforced carbon-carbon (RCC), used in the nose cap, the chin area between the nose cap and nose landing geardoors( 1,260 °c {2,300 °F))
  • 115.
  • 116. AUTOMOBILE • Engines bodies • Piston • Cylinder • connecting rod • crankshafts • bearing materials • brake discs
  • 117. CONSTRUCTION cost-effective and can withstand substantial compressive forces without breaking. Concrete
  • 118. CONSTRUCTION A laminar composite Plywood used in Bridge structures Fiber-Reinforced Polymers
  • 119. Medical Application • Orthopedic applications: bone fixation plates, hip joint replacement, bone cement, and bone grafts • External Prosthetics
  • 120. Medical Application • Composite materials are used in clinical practice to restore anterior and posterior teeth.
  • 121. Other Applications Electronics Sports equipments Marine Military applications