Composites manufacturing

November 3, 2018November 3, 2018
STC on Emerging Technologies inSTC on Emerging Technologies in
Mechanical EngineeringMechanical Engineering 11
Manufacturing of CompositesManufacturing of Composites
byby
Dr. S. KamaluddinDr. S. Kamaluddin
Department of ME, GU, VisakhapatnamDepartment of ME, GU, Visakhapatnam

Types of CompositesTypes of Composites
 Polymer Matrix CompositesPolymer Matrix Composites
 Metal – Matrix CompositesMetal – Matrix Composites
 Ceramic Matrix CompositesCeramic Matrix Composites
 Carbon – Carbon CompositesCarbon – Carbon Composites

Polymer Matrix CompositesPolymer Matrix Composites

Matrix materials:Matrix materials:
Thermo sets (Epoxy Resins, UnsaturatedThermo sets (Epoxy Resins, Unsaturated
Polysters, Vinyl Easters)Polysters, Vinyl Easters)
Thermo plasticsThermo plastics
Reinforcements:Reinforcements:
1.Glass fiber1.Glass fiber (SiO(SiO22 above 99.5%, Highabove 99.5%, High
melting Temperature, Low coefficient ofmelting Temperature, Low coefficient of
expansion, thermally shock resistant)expansion, thermally shock resistant)
2.Carbon fiber2.Carbon fiber
3.Aramid or Kevlar (Long chain molecules)3.Aramid or Kevlar (Long chain molecules)

Processing of Thermo set matrixProcessing of Thermo set matrix
compositescomposites
1.1. Hand Lay Up TechniquesHand Lay Up Techniques
2.2. Spray Up TechniqueSpray Up Technique
3.3. Filament WeldingFilament Welding
4.4. PultrusionPultrusion
5.5. Autoclave – Based MethodAutoclave – Based Method

Hand Lay Up TechniquesHand Lay Up Techniques

Spray Up TechniqueSpray Up Technique

Filament WeldingFilament Welding

PultrusionPultrusion

Thermo Plastic Matrix CompositesThermo Plastic Matrix Composites
1.1. Injection MouldingInjection Moulding
2.2. ExtrusionExtrusion

Applications of PMCsApplications of PMCs
1.1. Sporting goodsSporting goods
2.2. Civil Construction to AerospaceCivil Construction to Aerospace
3.3. Aircraft doors, flooringAircraft doors, flooring
4.4. Tanks and vessels (Pressure andTanks and vessels (Pressure and
Non pressure)Non pressure)
5.5. Process and effluent pipe lines inProcess and effluent pipe lines in
chemical industrychemical industry

Fiber glass/resin structural shapes made by pultrusion

Drumsticks made with a pultruded Kevlar core and a thermo plastic
injection moulded cover

Use of PMCs in a helicopter

ApplicationsApplications
Children's Chair
Retail Cooler
11/14
Playground Equipment

Fuel Tank
Insulated Hot Water Tank
Coffee Display
Industrial Tilt Truck
12/14

Metal Matrix CompositesMetal Matrix Composites

Types of MMCsTypes of MMCs
 Particle reinforcedParticle reinforced
 Short fibers or whisker reinforcedShort fibers or whisker reinforced
 Continuous fiber or sheetContinuous fiber or sheet
reinforcedreinforced

Type Aspect
ratio
Diameter,
μ m
Examples
Particle 1 - 4 1 - 25 SiC, Al2
O3
,
BN,B4
C
Short fibers or
whiskers
10 - 1000 0.1 - 25 SiC, Al2
O3
SiC+
Al2
O3,
Carbon
Continuous
fibers
Above
1000
3 – 150 SiC, Al2
O3 ,
Carbon,
Tungsten

Metallic Materials (Matrix materials)Metallic Materials (Matrix materials)
1.1. Al and its alloys (Density 2.71 gm/cc)Al and its alloys (Density 2.71 gm/cc)
2.2. Ti alloys (4.5 gm/cc)Ti alloys (4.5 gm/cc)
3.3. Mg alloys (1.74 gm/cc)Mg alloys (1.74 gm/cc)
4.4. CopperCopper
5.5. IntermetallicsIntermetallics

Processing of the MMCsProcessing of the MMCs
1.1. Liquid state processingLiquid state processing
– i. Duralcan processi. Duralcan process
– ii. Spray formingii. Spray forming
– iii. Squeeze casting (or) pressureiii. Squeeze casting (or) pressure
infiltrationinfiltration
– iv. Stir castingiv. Stir casting
1.1. Solid state processingSolid state processing
- i. Diffusion bonding process- i. Diffusion bonding process

Duralcan processDuralcan process

ProcedureProcedure
 Stage 1. Aluminium + ceramic particlesStage 1. Aluminium + ceramic particles
(8 – 12 μm) particles mixing(8 – 12 μm) particles mixing
 Stage 2. Melting in a furnaceStage 2. Melting in a furnace
 Stage 3. Stirring at 700Stage 3. Stirring at 70000
CC
 Stage 4 . CastingStage 4 . Casting
 Stage 5. secondary operation for furtherStage 5. secondary operation for further
deformation like rolling, extrusion etc.deformation like rolling, extrusion etc.

Spray formingSpray forming

ProcedureProcedure
 Stage 1Stage 1: Spray gun is used to: Spray gun is used to
atomize the molten aluminium alloyatomize the molten aluminium alloy
matrixmatrix
 Stage 2Stage 2: Reinforcement is preheated: Reinforcement is preheated
ceramic particles (SiC) are injectedceramic particles (SiC) are injected
into this molten Streaminto this molten Stream
 Stage 3Stage 3: Final Product - Porous: Final Product - Porous
perform, it is further undergo for theperform, it is further undergo for the
secondary finishing operations.secondary finishing operations.

Advantages:Advantages:
1. Flexibility that it affords in making different1. Flexibility that it affords in making different
types of compositestypes of composites
2. Simultaneously two sprayers can be done2. Simultaneously two sprayers can be done
3. Volume fraction up to 20% can be incorporated3. Volume fraction up to 20% can be incorporated
DisadvantagesDisadvantages
1. Porous product1. Porous product
2. High cost of capital and operational.2. High cost of capital and operational.

Squeeze casting (or) Pressure infiltrationSqueeze casting (or) Pressure infiltration
processprocess
(a) Press forming of a preform

ProcedureProcedure
Stage 1. Preform makingStage 1. Preform making
(Press Forming)(Press Forming)
– Aqueous slurry making (water +Aqueous slurry making (water +
Binder + fibers)Binder + fibers)
– Well mixed in the containerWell mixed in the container
– Pouring the mix into a mouldPouring the mix into a mould
– Pressure applied on the slurry to waterPressure applied on the slurry to water
outout
– Preform is driedPreform is dried

Stage 2. Squeeze castingStage 2. Squeeze casting
- Porous perform is inserted into the die- Porous perform is inserted into the die
- Molten metal (Al) is poured into the- Molten metal (Al) is poured into the
preheated diepreheated die
- Application of the pressure (70 – 100 MPa)- Application of the pressure (70 – 100 MPa)
- Aluminium penetrate the fiber perform- Aluminium penetrate the fiber perform
and bond the fibersand bond the fibers
- Argon gas is used to prevent the air- Argon gas is used to prevent the air
infiltration into the mouldinfiltration into the mould

Squeeze casting technique of composite fabrication

AdvantagesAdvantages
 Low porosityLow porosity
 No shrinkage cavityNo shrinkage cavity
 Minimum reaction between matrixMinimum reaction between matrix
and the particles due to short dwelland the particles due to short dwell
times.times.

Stir Cast TechniqueStir Cast Technique
Procedure:Procedure:
(a) Molten metal making(a) Molten metal making
(b) Preheated particle addition(b) Preheated particle addition
(c) Stirring(c) Stirring
(d) Bottom casting of the composite(d) Bottom casting of the composite

Solid state ProcessSolid state Process
 Diffusion bonding at highDiffusion bonding at high
temperature to weld similar ortemperature to weld similar or
dissimilar metalsdissimilar metals

The microstructure of SiC fiber/Titanium matrix composite
made by diffusion bonding (Fiber diameter is 142 µm )

Applications of MMCsApplications of MMCs
1.1. Aerospace applicationsAerospace applications
I.I. Low densityLow density
II.II. High stiffnessHigh stiffness
III.III. High strengthHigh strength
IV.IV. Low thermal expansionLow thermal expansion
1.1. Automobile IndustryAutomobile Industry
I.I. Light weightLight weight
II.II. High wear resistantHigh wear resistant
III.III. Low thermal expansionLow thermal expansion

Ceramic Matrix CompositesCeramic Matrix Composites

- High strength at high temperature- High strength at high temperature
- High stiffness at high temperature- High stiffness at high temperature
- Chemical inertness- Chemical inertness
- Low density- Low density
- Extremely susceptible to thermal shock- Extremely susceptible to thermal shock
- Easily damaged during fabrication- Easily damaged during fabrication
- Toughness is very poor- Toughness is very poor

The matrix materialsThe matrix materials
1.1. Single oxides:Single oxides:
Aluminium oxide,Aluminium oxide,
ZirconiaZirconia
TitaniaTitania
Magnesium oxideMagnesium oxide
SilicaSilica
2.2. Mixed oxidesMixed oxides
MulliteMullite
SpinelSpinel
3. Carbides3. Carbides
Silicon carbideSilicon carbide
Boron carbideBoron carbide
Titanium carbideTitanium carbide
4. Nitrides4. Nitrides
Boron nitrideBoron nitride
Silicon nitrideSilicon nitride
5. Intermetallics5. Intermetallics
Nickel aluminideNickel aluminide
Titanium aluminideTitanium aluminide
Molybdenum disilicideMolybdenum disilicide
6. Elemental6. Elemental
CarbonCarbon
BoronBoron

Processing of CMCsProcessing of CMCs
1. Cold pressing and Sintering1. Cold pressing and Sintering
2. Hot Pressing2. Hot Pressing
3. Infiltration (Liquid Infiltration)3. Infiltration (Liquid Infiltration)
4. LANXIDE or DIMOX or Direct4. LANXIDE or DIMOX or Direct
Oxidation ProcessOxidation Process

Cold pressing and SinteringCold pressing and Sintering
Stage1:Stage1: Cold pressing of matrixCold pressing of matrix
powder and fiberpowder and fiber
Stage2:Stage2: Sintering at high temperatureSintering at high temperature

1. Due to Matrix shrinkage thermal cracks will1. Due to Matrix shrinkage thermal cracks will
generatesgenerates
2. Hydrostatic tensile stresses will generates during2. Hydrostatic tensile stresses will generates during
cooling (due to differential thermal expansions ofcooling (due to differential thermal expansions of
matrix and reinforcement)matrix and reinforcement)
3. Poor densification rates of composites3. Poor densification rates of composites

Hot Pressing (Slurry Infiltration Process)Hot Pressing (Slurry Infiltration Process)

ProcedureProcedure
Stage 1 :Stage 1 : Fiber perform is impregnated with aFiber perform is impregnated with a
matrix slurry (Matrix powder, water ormatrix slurry (Matrix powder, water or
alcohol and organic binder)alcohol and organic binder)
Stage 2 :Stage 2 : Binder burningBinder burning
Stage 3 :Stage 3 : The prepreg is wound on drum and driedThe prepreg is wound on drum and dried
Stage4 :Stage4 : Cutting and stacking of the prepregsCutting and stacking of the prepregs
(Unidirectional, cross piled 0/90/0/90,(Unidirectional, cross piled 0/90/0/90,
Angle piled, +Angle piled, +θθ,-,- θθ,+,+ θθ,-,- θθ))
Stage 5Stage 5 : Hot pressing at high temperature(1000: Hot pressing at high temperature(100000
CC
and 3 MPa)and 3 MPa)

Optical micrograph of transverse section of a
unidirectional Ncalon fiber/Glass matrix

1 Fairly uniform fiber distribution1 Fairly uniform fiber distribution
2 Low porosity2 Low porosity
3 High strength3 High strength

Infiltration (Liquid Infiltration)Infiltration (Liquid Infiltration)

ProcedureProcedure
Stage 1.Stage 1. Preform making by using Fibers,Preform making by using Fibers,
whiskers and particleswhiskers and particles
Stage 2 :Stage 2 : Hot ceramic metal in liquid formHot ceramic metal in liquid form
is passed into perform whileis passed into perform while
applying the pressure.applying the pressure.

1. The matrix formed in a single processing step1. The matrix formed in a single processing step
2. A homogenous matrix can be obtained2. A homogenous matrix can be obtained
Disadvantages:Disadvantages:
1. Due to high temperature possibilities of chemical1. Due to high temperature possibilities of chemical
reactions between the matrix and reinforcements.reactions between the matrix and reinforcements.
2. Due to high viscosity of ceramics the infiltration into the2. Due to high viscosity of ceramics the infiltration into the
performs is difficult process.performs is difficult process.
3. The matrix is likely to crack because of the differential3. The matrix is likely to crack because of the differential
shrinkage between the matrix and the reinforcement onshrinkage between the matrix and the reinforcement on
solidification.solidification.

Carbon – Carbon CompositesCarbon – Carbon Composites

3 – Polymorphic forms of Carbon3 – Polymorphic forms of Carbon
1.1. DiamondDiamond
2.2. GraphiteGraphite (most abundantly available in(most abundantly available in
various forms like cokes, graphitevarious forms like cokes, graphite
electrodes, mechanical carbons, glassyelectrodes, mechanical carbons, glassy
carbons etc., with density varying 0.5 tocarbons etc., with density varying 0.5 to
2.2 gm/cc) and2.2 gm/cc) and
3.3. FullerenesFullerenes

1.1. Low densityLow density 1.6 to 2.0 gm/cc1.6 to 2.0 gm/cc
2.2. Light WeightLight Weight
3.3. High strengthHigh strength at high temperature (up toat high temperature (up to
3000300000
C) in non-oxygen atmosphereC) in non-oxygen atmosphere
4.4. Low Coefficient of thermal expansionLow Coefficient of thermal expansion
5.5. High thermal conductivityHigh thermal conductivity andand
6.6. High thermal shock resistanceHigh thermal shock resistance
7.7. Mechanical strength increases withMechanical strength increases with
temperaturetemperature

1.1. AerospaceAerospace and defence applicationsand defence applications
such as brake discs, rocket nozzles,such as brake discs, rocket nozzles,
furnace heating, thermalfurnace heating, thermal
components in space vehicles)components in space vehicles)
2.2. Bio-medicalBio-medical implantsimplants
3.3. Glass and ceramic industryGlass and ceramic industry

Tennis Racket, a pair of skis, a fishing rod

A bicycle frame made of carbon-carbon composite

Microphone made of carbon-carbon composite

A head shell unit of turntable arm made of carbon-carbon composite

Acknowledgements toAcknowledgements to
Department of Metallurgical Engineering, AUDepartment of Metallurgical Engineering, AU
Prof. NBR MOHAN RAO,Prof. NBR MOHAN RAO,
Dr.J. Babu Rao andDr.J. Babu Rao and
Dr. J. Appa RaoDr. J. Appa Rao

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