COMPOSITES TECHNOLOGY
(ENMT616028)
INTRODUCTION TO COMPOSITES MATERIALS
Prof. Dr. Ir. Anne Zulfia, M.Sc.
Departemen Metalurgi & Material
Fakultas Teknik Universitas Indonesia
Composite Materials
Fundamental considerations
• How do composite materials differ from other
engineering materials?
• What are the constituent materials, and how do
their properties compare?
• How do the properties of the composite depend
on the type, amount and arrangement of the
constituents?
• How are composite products made, and why
does manufacture affect quality?
COMPOSITES - A FORMAL DEFINITION
(Hull, 1981)
1. Consist of two or more physically distinct
and mechanically separable parts.
reinforcement
(discontinuous phase)
fibres or particles
short, ‘long’ or
continuous
+
matrix
(continuous phase)
COMPOSITES - A FORMAL DEFINITION
(Hull, 1981)
1. Consist of two or more physically distinct
and mechanically separable parts.
2. Constituents can be combined in a
controlled way to achieve optimum
properties.
COMPOSITES - A FORMAL DEFINITION
(Hull, 1981)
1. Consist of two or more physically distinct
and mechanically separable parts.
2. Constituents can be combined in a
controlled way to achieve optimum
properties.
3. Properties are superior, and possibly
unique, compare d those of the individual
components
Addition of properties:
GLASS + POLYESTER
= GRP
(strength) (chemical resistance)
(strength and
chemical
resistance)
Unique properties:
GLASS
(brittle)
+ POLYESTER
(brittle)
= GRP
(tough!)
Function of the Matrix
• Binds the fibers together
• Provides rigidity and shape to the structure
• Isolates fibers to slow crack propagation
• Surface quality
• Corrosion and wear protection for fibers
A matrix is required to:
• hold reinforcement in correct orientation
• protect fibres from damage
• transfer loads into and between fibres
Function of the Fiber
• Carry the load
– 70 to 90% of load carried by fibers
• Provide structural properties to the composite
– Stiffness
– Strength
– Thermal stability
• Provide electrical conductivity or insulation
Examples of particulate composites
• Concrete - hard particles (gravel) + cement (ceramic/ceramic
composite). Properties determined by particle size distribution,
quantity and matrix formulation
• Additives and fillers in polymers:
carbon black (conductivity, wear/heat resistance)
aluminium trihydride (fire retardancy)
glass or polymer microspheres (density reduction)
chalk (cost reduction)
• Cutting tool materials and abrasives (alumina, SiC, BN bonded
by glass or polymer matrix; diamond/metal matrix)
• Electrical contacts (silver/tungsten for conductivity and wear
resistance)
• Cast aluminium with SiC particles
•
•
•
•
•
•
•
ADVANCED COMPOSITES
vs
Aerospace, defence, F1…
Highly stressed
Glass, carbon, aramid fibres
Honeycomb cores
Epoxy, bismaleimide…
Prepregs
Vacuum bag/oven/autoclave
•
•
•
•
•
•
•
• Highly tested and qualified
materials
REINFORCED PLASTICS
Marine, building…
Lightly stressed
Glass (random and woven)
Foam cores
Polyester, vinylester…
Wet resins
Hand lay up, room temperature
cure
• Limited range of lower
performance materials
Methods of Reinforcing Plastics
Schematic illustration of methods of reinforcing plastics (matrix) with (a) particles, (b)
short or long fibers or flakes, and (c) continuous fibers. The laminate structures
shown in (d) can be produced from layers of continuous fibers or sandwich structures
using a foam or honeycomb core.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Characteristics of Composite Materials
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Why are composites used in engineering?
•
•
•
•
Weight saving (high specific properties)
Corrosion resistance
Fatigue properties
Manufacturing advantages:
- reduced parts count
- novel geometries
- low cost tooling
• Design freedoms
- continuous property spectrum
- anisotropic properties
Why aren’t composites used more in
engineering?
•
•
•
•
High cost of raw materials
Lack of design standards
Few ‘mass production’ processes available
No ‘off the shelf’ properties - performance
depends on quality of manufacture
Composites can be found in:
-Boat hulls
-The aerospace industry (structural components as
well as engines and motors)
-Automotive parts (panels, frames, dashboards,
body repairs)
-Sinks, bathtubs, hot tubs, swimming pools
-Cement buildings, bridges
-Surfboards, snowboards, skis
-Golf clubs, fishing poles, hockey sticks
-Trees are technically composite materials, plywood
-Electrical boxes, circuit boards, contacts
-Everywhere
Boeing 757-200
Application of advanced composite materials in Boeing 757-200 commercial aircraft.
Source: Courtesy of Boeing Commercial Airplane Company.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Aluminium
or
composite?
2005: Airbus engineers are
claiming Boeing has rushed the
development of the 7E7
Dreamliner. In particular, they
say composite technology is not
mature enough to build an allcomposite fuselage. But the
claims may be no more than a
marketing ploy, in response to
Boeing's criticism of weight
overruns on the Airbus A380.
Metal (steel,
aluminium,
titanium,
magnesium…)
Composite (carbon
fibre / epoxy)?
Composite – wood, glass, carbon?
Manufacture - prepreg, infusion…?
COMPOSITES MARKETS
•
•
•
•
•
•
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TRANSPORTATION
CONSTRUCTION
MARINE
CORROSION-RESISTANT
CONSUMER
ELECTRICAL/ELECTRONIC
APPLIANCES/BUSINESS
AIRCRAFT/DEFENSE
Infrastructure Benefits
•
•
•
•
•
•
•
•
•
•
•
HIGH STRENGTH/WEIGHT RATIO
ORIENTATED STRENGTH
DESIGN FLEXIBILITY
LIGHTWEIGHT
CORROSION RESISTANCE
LOW MAINTENANCE/LONG-TERM DURABILITY
LARGE PART SIZE POSSIBLE
TAILORED AESTHETIC APPEARANCE
DIMENSIONAL STABILITY
LOW THERMAL CONDUCTIVITY
LOW INSTALLED COSTS
ADVANTAGES OF COMPOSITES
(for construction applications)
Aesthetic appeal
Ability to mould complex shapes
Various surface finishes available
Lightweight
Durability / Corrosion resistance
Parts integration
Cost effectiveness
Electrical properties
POSSIBLE APPLICATIONS
(in construction)
Roofs / canopies
Complete buildings
Cladding panels
Masts & towers
Domes
Unusual architectural features / structures
Radomes
Permanent or temporary formwork
Strengthening / repair of conventional structures
Tanks, covers, pipes, ducts etc
BRIDGE APPLICATIONS OF COMPOSITE MATERIALS
GRP LOUVRES AT LANCASTER UNIVERSITY
HARARE INTERNATIONAL AIRPORT
ARCHITECTURAL GRP STRUCTURE ON
THE TOP OF THE AIR TRAFFIC CONTROL
TOWER
FRP
MOSQUE
DOMES
PHOTOS COURTESY OF NORTHSHORE COMPOSITES
MILLENNIUM DOME
HOME PLANET ZONE
FRP
SPHERICAL
RADOMES
FRP CYLINDRICAL
RADOMES
GLASGOW SCIENCE
CENTRE
FRP OBSERVATION CABIN
&
CARBON FIBRE
MAST
Photo - Carrillion
CABIN MANUFACTURE
CABIN INSTALLATION
CONCRETE COLUMN REINFORCEMENT
FRP LIGHTSTATIONS
FRP BRIDGE ENCLOSURES
FRP PULTRUDED STRUCTURAL
FRAME
PORTSMOUTH SPINNAKER
TOWER
SPIRE SECTION MAY
BE MANUFACTURED
IN COMPOSITES