This document provides information on composite materials, including definitions, classifications, properties, advantages, limitations, and manufacturing processes. It defines a composite as a combination of two or more materials that results in improved properties over the individual components. Composites are classified based on their matrix material, such as polymer matrix composites, metal matrix composites, ceramic matrix composites, and carbon/carbon composites. The document discusses the various types of reinforcements and fillers used in composites, as well as the functions of the matrix and factors affecting composite properties. It also outlines the advantages of composites over metallic materials, some limitations, and applications in engineering. Finally, the stages of the manufacturing process for composites are briefly described.

1. Sanjivani Rural Education Society’s
Sanjivani College of Engineering, Kopargaon-423 603
(An Autonomous Institute, Affiliated to Savitribai Phule Pune University, Pune)
NAAC ‘A’ Grade Accredited, ISO 9001:2015 Certified
Department of Mechanical Engineering
Subject :- Materials Science & Metallurgy (MSM)
S.Y. Mechanical
Unit 6- INTRODUCTION TO ADVANCED MATERIALS
6.1 Composites
Dr. S. R. Thorat
Assistant Professor
E-mail : thoratsandipmech@sanjivani.org.in

2. TOPIC-6.01
6.1 Composites:
• Basic concepts of composites
• Various types/Classification of composites

3. • A composite material can be defined as a combination of two or more
materials (having significantly different physical or chemical properties)
that results in better properties than those of the individual components.
• The constituents retain their identities in the composite; that is, they do not
dissolve or otherwise merge completely into each other, although they act in
concert.
• Composites are one of the most widely used materials because of their
adaptability to different situations and the relative ease of combination with
other materials to serve specific purposes and exhibit desirable properties.
• The main advantages of composite materials are their high strength and
stiffness, combined with low density, when compared with bulk materials.
INTRODUCTION

4. The composites are classified as mainly two constituents are matrix and a reinforcement
CLASSIFICATION OF COMPOSITE MATERIALS

5. Two main kinds of polymers are thermosets and thermoplastics
• Thermosets have qualities such as a well-bonded three dimensional
molecular structure after curing. They decompose instead of melting on
hardening.
• Thermoplastics have one or two dimensional molecular structure and
they tend to at an elevated temperature and show exaggerated melting
point. Another advantage is that the process of softening at elevated
temperatures can reversed to regain its properties during cooling.
ORGANIC/POLYMER MATRIX COMPOSITE (PMCs)

6.  Metal matrix composites are High strength, fracture toughness and stiffness are offered by metal
matrices than those offered by their polymer counterparts. They can withstand elevated
temperature in corrosive environment than polymer composites.
 MMCs are widely used in engineering applications where the operating temperature lies in
between 250 ºC to 750 ºC.
 Matrix materials: Steel, Aluminum, Titanium, Copper, Magnesium and Super alloys.
 Ceramics can be described as solid materials which exhibit very strong ionic bonding in general
and in few cases covalent bonding. High melting points, good corrosion resistance, stability at
elevated temperatures and high compressive strength
 CMCs are widely used in engineering applications where the operating temperature lies in
between 800ºC to 1650ºC
METAL MATRIX COMPOSITE (MMCs)
CERAMIC MATRIX COMPOSITE (CMCs)

7.  C/Cs are developed specifically for parts that must operate in extreme temperature
ranges. Composed of a carbon matrix reinforced with carbon yarn fabric, 3-D woven
fabric, 3-D braiding, etc.
 C/C composites meet applications ranging from rockets to aerospace because of their
ability to maintain and even increase their structural properties at extreme
temperatures.
Advantages:
• Extremely high temperature resistance (1930°C – 2760°C).
• Strength actually increases at higher temperatures (up to 1930°C).
• High strength and stiffness.
• Good resistance to thermal shock.
CARBON/CARBON MATRIX COMPOSITE

8. • Holds the fibers together.
• Protects the fibers from environment.
• Distributes the loads evenly between fibers so that all fibers are
subjected to the same amount of strain.
• Enhances transverse properties of a laminate.
• Improves impact and fracture resistance of a component.
• Carry inter laminar shear.
• Reduced moisture absorption.
• Low shrinkage.
• Low coefficient of thermal expansion.
• Strength at elevated temperature (depending on application).
• Low temperature capability (depending on application).
• Excellent chemical resistance (depending on application).
FUNCTIONS OF A MATRIX
DESIRED PROPERTIES OF A MATRIX

9. CLASSIFICATION OF COMPOSITE MATERIALS

10. Fibers are the important class of reinforcements, as they satisfy the desired conditions and
transfer strength to the matrix constituent influencing and enhancing their properties as desired.
Random fiber (short fiber) reinforced composites
Continuous fiber (long fiber) reinforced composites
FIBER REINFORCED COMPOSITES

11. Laminar composites are found in as many combinations as the number of materials.
They can be described as materials comprising of layers of materials bonded together.
These may be of several layers of two or more metal materials occurring alternately or
in a determined order more than once, and in as many numbers as required for a specific
purpose.
LaminarComposite Sandwich Composite
LAMINAR COMPOSITES

12. • Microstructures of metal and ceramics composites, which show particles of one phase
strewn in the other, are known as particle reinforced composites.
• Square, triangular and round shapes of reinforcement are known, but the dimensions of
all their sides are observed to be more or less equal. The size and volume concentration of
the dispersed distinguishes it from dispersion hardened materials.
Particulate reinforcedcomposites
PARTICULATE REINFORCED COMPOSITES

13. • Flakes are often used in place of fibers as can be densely packed.
• Metal flakes that are in close contact with each other in polymer matrices can conduct
electricity or heat, while mica flakes and glass can resist both.
• Flakes are not expensive to produce and usually cost less than fibers.
Flake composites
FLAKE COMPOSITES

14. • Fillers may be the main ingredient or an additional one in a composite.
• The filler particles may be irregular structures, or have precise geometrical shapes
like polyhedrons, short fibers or spheres.
FILLED COMPOSITES

15. • Microspheres are considered to be some of the most useful fillers.
• Their specific gravity, stable particle size, strength and controlled density to modify products
without compromising on profitability or physical properties are it’s their most-sought after
assets.
• Solid Microspheres have relatively low density, and therefore, influence the commercial value
and weight of the finished product.
• Studies have indicated that their inherent strength is carried over to the finished molded part of
which they form a constituent.
• Hollow microspheres are essentially silicate based, made at controlled specific gravity.
• They are larger than solid glass spheres used in polymers and commercially supplied in a wider
range of particle sizes.
MICROSPHERES

16. FACTORS AFFECTING PROPERTIES OF COMPOSITES
• The type, distribution, size, shape, orientation and arrangement of the reinforcement will
affect the properties of the composites material and its anisotropy
Distribution Concentration Orientation
Shape
Size

17. TOPIC-6.02
6.1 Composites:
• Advantages over metallic materials and Limitations
• Processing/manufacturing of composites
• Composites-applications

18. ADVANTAGES
 Light in weight and Lower density
 High creep resistance
 Strength-to-weight and Stiffness-to-weight are greater than steel or aluminum
 Fatigue properties are better than common engineering metals
 Composites cannot corrode like steel
 Ease of fabrication of large complex structural shapes or modules-Modular
construction
 Ability to incorporate sensors in the material to monitor and correct its performance-
Smart composites
 High resistance to impact damage.
 Improved corrosion resistance

19.  High cost of raw materials and fabrication.
 Composites are more brittle than wrought metals and thus are more easily damaged.
 Transverse properties may be weak.
 Matrix is weak, therefore, low toughness.
 Reuse and disposal may be difficult.
 Difficult to attach.
 Difficulty with analysis
 Cost can fluctuate.
LIMITATIONS

20. COMPOSITES:PROCESSING / MANUFACTURE
Composites consist of two distinct materials, which together improve product
performance and lower production costs.
Composite materials typically include plated, clad, or coated metals, however the term
'composites' has evolved to mean a material containing a matrix, or base substance, and a
reinforcement material.
The matrix acts as a binder for the reinforcement while controlling the physical shape
and dimensions of the part.
Its primary purpose however is to transfer the load, or stress, applied to the part to the
reinforcement.
The matrix also protects the reinforcement from adverse environmental effects.

21. The reinforcement’s function is to enhance the mechanical properties of the composite
and is typically the main load bearing element.
Reinforcements are usually in the form of either fibers or particles.
Matrix and reinforcement materials can be polymers, metals, ceramics, or carbon.
The most widely used composite materials are fiber- reinforced thermosetting polymers.
A composite can be defined as a combination of two or more materials that retain their
macro-structure resulting in a material that can be designed to have improved properties
than the constituents alone.

22. Advanced composite materials have been used to fabricate many structural parts in
engineering applications.
This is due to their many attractive characteristics such as light weight, high strength,
high stiffness, good fatigue resistance and good corrosion resistance.
Also, the ability to manufacture parts with complicated geometry using fewer
components enables manufacturers to save cost as compared with the same parts made
of conventional metallic materials.

23. STAGES OF MANUFACTURING COMPOSITES
Stage a:At this stage, the materials
appear in raw basic form.
For fibers, these consist of fiber either in
the form of filaments or fiber bundles.
Fibers may also be woven into fabrics or
braided into braided perform.
For matrix, the material usually appears in
liquid form for thermoset resin or in
granular form in the case of
thermoplastics.

24. STAGES OF MANUFACTURING COMPOSITES
Stage b: At this stage, the fibers and
matrix may be combined into a
single layer.
For the case of thermoset matrix
composite,the matrix may appear
in a semi-liquid, semi-solid form so
that the sheet can hold its shape.
For the case of thermoplastic
composite, the matrix is solidified.
This form for thermoset matrix
composites is called prepreg. For
thermoplastic composites, it is
called towpreg.

25. Stage c: At this stage, the layers in
stage b are stacked on top of each
other to make flat plate laminates. This
intermediate step is important for the
analysis where material properties are
tested or calculated. However this step
is usually bypassed in the
manufacturing process of practical
composite parts.
Stage d: This is the final stage where
the final product configuration is
formed.

26. VARIOUS TECHNIQUES OF MANUFACTURING
 Hand lay up Technique
 Pressure bag and vacuum bag technique
 Pultrusion
 Resin – transfer Moulding
 Injection Moulding

27. TOPIC-6.03
6.1 Composites:
• Composites-applications

28. APPLICATIONS OF COMPOSITE MATERIALS
Glass fibre reinforced polymer composites:
• Automotive and marine bodies
• Leaf springs
• Sporting goods
• Storage containers
• Industrial floorings
• Bathroom shower tubes
• Chairs
Varade H.P. Department Of Mechanical Engineering, Sanjivani COE, Kopargaon

29. APPLICATIONS OF COMPOSITE MATERIALS
Aramid fibre reinforced polymer composites:
• Bullet proof vests
• Pressure vessels
• Missile cases
• Automotive brakes and clutch linings
• Gaskets
• Sports shoes
Varade H.P. Department Of Mechanical Engineering, Sanjivani COE, Kopargaon

30. APPLICATIONS OF COMPOSITE MATERIALS
Carbon fibre reinforced polymer composites:
• Golf sticks
• Fishing rods
• Air craft and helicopter components
• Motor cases
Varade H.P. Department Of Mechanical Engineering, Sanjivani COE, Kopargaon

31. APPLICATIONS OF COMPOSITE MATERIALS
Metal matrix composites:
• Aluminium reinforced with alumina fibers are used in automotive
connecting rods and pistons
• Aluminium reinforced with silicon carbide are used in aircraft wing
panels.
• Copper reinforced with silicon carbide fibers are used in propellers of
ships.
• Titanium reinforced with silicon carbide fibres are used for turbine
blades and discs.
Varade H.P. Department Of Mechanical Engineering, Sanjivani COE, Kopargaon

32. APPLICATIONS OF COMPOSITE MATERIALS
Ceramic matrix composites:
• Alumina reinforced with SiC (silicon carbide) is used as cutting tool
inserts for machining hard metal alloys.
• Used for high temperature applications like gas turbines and IC
engines.
Varade H.P. Department Of Mechanical Engineering, Sanjivani COE, Kopargaon

33. APPLICATIONS OF COMPOSITE MATERIALS
Carbon carbon composites:
• Rocket motors
• Brake discs of racing cars and aircrafts
• Leading edges of aerospace vehicles
Hybrid composites:
• Fishing rod is made of carbon aramid reinforced plastic
• Bicycle frame is made of glass carbon reinforced epoxy
Varade H.P. Department Of Mechanical Engineering, Sanjivani COE, Kopargaon

34. THANK YOU !!!