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COMPOSITE MATERIALS AND APPLICATIONS
Kendari, 8 Oktober 2015
Prodi TEKNIK MESINUNIVERSITAS HALUOLEO
Prof. Ir. Hadi Sutanto, MMAE., Ph.D.
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OUTLINE
• COMPOSITE MATERIALS: Classes and types of compositesStrength of compositesComposite productions
• APPLICATIONS
• INTRODUCTION
INTRODUCTION
ENGINEERING MATERIALS
METALS: FERROUS & NON FERROUS CERAMICS & GLASSES POLYMERS & ELASTOMERS COMPOSITES
History of Materials Science & Engineering• materials closely connected our culture• the development and advancement of societies are dependent on the
available materials and their use• earl y civil izations designated by level of materials development
• initially natural materials• develop techniques to produce materials with superior qualities (heat
treatments and addition of other substances)6
History of Materials Science & Engineering
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Brick : Ramses II, EGYPT 1279 - 1212 BC
Material productionConcern 1: Resource consumption, dependence
96% of all material Usage
20% of Globalenergy
Sources: Granta Design, Cambridge, UK.
Carbon to atmosphereConcern 2: Energy consumption, CO2 emission
20% of allcarbon toatmosphere
Sources: Granta Design, Cambridge, UK.
Why study materials?• applied scientists or engineers must make material choices
• materials selection
– in-service performance
– deterioration
– economics
BUT…really, everyone makes material choices!
aluminum glass plastic
Materials Science and Engineering
structure
properties• material characteristic• response to external
stimulus
• mechanical, electrical,
thermal, magnetic,
optical, deteriorative performance• behavior in a particular
application
• arrangement of internal components
• subatomic• atomic
• microscopic
• macroscopic (bulk)
• method of
preparing material
processing
characterization
TETRAHEDRON
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© 20 03 Bro oks /Cole Pub lish ing / Tho mso n Learn ing™
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Application of the tetrahedron of materials science and engineering to sheet steels for automotive chassis. Note that the microstructure-synthesis and processing-composition are all interconnected and affect the performance-to-cost ratio
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ex: hardness vs structure of steel• Properties depend on structure
Data obtained from Figs. 10.30(a)and 10.32 with 4 wt% C composition,and from Fig. 11.14 and associateddiscussion, Callister 7e.Micrographs adapted from (a) Fig.10.19; (b) Fig. 9.30;(c) Fig. 10.33;and (d) Fig. 10.21, Callister 7e.
ex: structure vs cooling rate of steel• Processing can change structure
Structure, Processing, & Properties
Har
dn
ess
(B
HN
)
Cool ing Rate (ºC/s)
100
200
300
400
500
600
0.01 0.1 1 10 100 1000
(d)
30 mm(c)
4 mm
(b)
30 mm
(a)
30 mm
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1. Pick Application Determine required Properties
2. Properties Identify candidate Material(s)
3. Material Identify required Processing
Processing: changes structure and overall shapeex: casting, sintering, vapor deposition, doping
forming, joining, annealing.
Properties: mechanical, electrical, thermal,magnetic, optical, deteriorative.
Material: structure, composition.
The Materials Selection Process
COMPOSITE MATERIALS
Venn diagram of three basic material types plus composites
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Composites• Combine materials with the objective of
getting a more desirable combination of properties
– Ex: get flexibility & weight of a polymer plus the strength of a ceramic
• Principle of combined action
– Mixture gives “averaged” properties
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Some examples of composite materials: (a) plywood is a laminar composite of layers of wood veneer, (b) fiberglass is a fiber-reinforced composite containing stiff, strong glass fibers in a softer polymer matrix ( 175), and (c) concrete is a particulate composite containing coarse sand or gravel in a cement matrix (reduced 50%).
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• Composites:-- Multiphase material w/significant
proportions of each phase.
• Dispersed phase:-- Purpose: enhance matrix properties.
MMC: increase y, TS, creep resist.CMC: increase KcPMC: increase E, y, TS, creep resist.
-- Classification: Particle, fiber, structural
• Matrix:-- The continuous phase-- Purpose is to:
- transfer stress to other phases- protect phases from environment
-- Classification: MMC, CMC, PMC
metal ceramic polymer
Reprinted with permission fromD. Hull and T.W. Clyne, An Introduction to Composite Materials, 2nd ed., Cambridge University Press, New York, 1996, Fig. 3.6, p. 47.
Terminologywoven fibers
cross section view
0.5 mm
0.5 mm
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Composite Survey
Large-
particle
Dispersion-
strengthened
Particle-reinforced
Continuous
(aligned)
Aligned Randomlyoriented
Discontinuous
(short)
Fiber-reinforced
Laminates Sandwich
panels
Structura l
Composites
Adapted from Fig. 16.2, Callister 7e.
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Composite Survey: Particle-I
• Examples:Adapted from Fig. 10.19, Callister 7e. (Fig. 10.19 is copyright United States Steel Corporation, 1971.)
- Spheroidite steel
matrix: ferrite (a)
(ductile)
particles: cementite(Fe 3 C )
(brittle)60 mm
Adapted from Fig. 16.4, Callister 7e. (Fig. 16.4 is courtesy Carboloy Systems, Department, General Electric Company.)
- WC/Co cemented carbide
matrix: cobalt (ductile)
particles: WC (brittle, hard)V m :
10-15 vol%! 600 mm
Adapted from Fig. 16.5, Callister 7e. (Fig. 16.5 is courtesy Goodyear Tire and Rubber Company.)
- Automobile tires
matrix: rubber (compliant)
particles: C (stiffer)
0.75 mm
Particle-reinforced Fiber-reinforced Structural
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Composite Survey: Particle-II
Concrete – gravel + sand + cement- Why sand and gravel? Sand packs into gravel voids
Reinforced concrete - Reinforce with steel rerod or remesh- increases strength - even if cement matrix is cracked
Prestressed concrete - remesh under tension during setting of concrete. Tension release puts concrete under compressive force
- Concrete much stronger under compression. - Appl ied tension must exceed compressive force
Particle-reinforced Fiber-reinforced Structural
threadedrod
nut
Post tensioning – tighten nuts to put under tension
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• Elastic modulus, Ec, of composites:-- two approaches.
• Application to other properties:-- Electrical conductivity, e: Replace E in equations with e.-- Thermal conductivity, k: Replace E in equations with k.
Adapted from Fig. 16.3, Callister 7e. (Fig. 16.3 is from R.H. Krock, ASTM Proc, Vol. 63, 1963.)
Composite Survey: Particle-III
lower limit:
1
E c
=Vm
E m
+Vp
E p
c m m
upper limit:
E = V E + VpE p
“rule of mixtures”
Particle-reinforced Fiber-reinforced Structural
Data: Cu matrix
w/tungsten particles
0 20 40 6 0 80 10 0
150
20 0
250
30 0
350
vol% tungsten
E(GPa)
(Cu) (W)
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Composite Survey: Fiber-I
• Fibers very strong– Provide significant strength improvement to material
– Ex: fiber-glass
• Continuous glass filaments in a polymer matrix
• Strength due to fibers
• Polymer simply holds them in place
Particle-reinforced Fiber-reinforced Structural
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Composite Survey: Fiber-II
• Fiber Materials– Whiskers - Thin single crystals - large length to diameter ratio
• graphite, SiN, SiC
• high crystal perfection – extremely strong, strongest known• very expensive
Particle-reinforced Fiber-reinforced Structural
– Fibers
• polycrystalline or amorphous
• generally polymers or ceramics
• Ex: Al2O3 , Aramid, E-glass, Boron, UHMWPE
– Wires
• Metal – steel, Mo, W
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Fiber Alignment
aligned
continuous
aligned random
discontinuous
Adapted from Fig. 16.8, Callister 7e.
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• Aligned Continuous fibers• Examples:
From W. Funk and E. Blank, “Creep deformation of Ni3Al-Mo in-situ composites", Metall. Trans. A Vol. 19(4), pp. 987-998, 1988. Used with permission.
-- Metal: g'(Ni3Al )-a(Mo)by eutectic solidification.
Composite Survey: Fiber-III
Particle-reinforced Fiber-reinforced Structural
matrix: a (Mo) (ductile)
fibers: g’ (Ni3Al ) (brittle)
2 mm
-- Ceramic: Glass w/SiC fibersformed by glass slurry
Eglass = 76 GPa; ESiC = 400 GPa.
(a)
(b)
fracture surface
From F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig. 4.22, p. 145 (photo by J . Davies); (b) Fig. 11.20, p. 349 (micrograph by H.S. Kim, P.S. Rodgers, and R.D. Rawlings). Used with permission of CRCPress, Boca Raton, FL.
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• Discontinuous, random 2D fibers• Example: Carbon-Carbon
-- process : fiber/pitch, thenburn out at up to 2500ºC.
-- uses: disk brakes, gas turbine exhaust flaps, nosecones.
• Other variations:-- Discontinuous, random 3D-- Discontinuous, 1D
Adapted from F.L. Matthews and R.L. Rawlings, Composite Materials; Engineering and Science, Reprint ed., CRC Press, Boca Raton, FL, 2000. (a) Fig. 4.24(a), p. 151; (b) Fig. 4.24(b) p. 151. (Courtesy I.J. Davies) Reproduced with permission of CRC Press, Boca Raton, FL.
Composite Survey: Fiber-IV
Particle-reinforced Fiber-reinforced Structural
(b)
fibers lie
in plane
view onto plane
C fibers:
very stiff very strong
C matrix:
less stiff less strong
(a)
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• Critical fiber length for effective stiffening & strengthening:
• Ex: For fiberglass, fiber length > 15 mm needed
Composite Survey: Fiber-V
Particle-reinforced Fiber-reinforced Structural
c
fd
15length fiber
fiber diameter
shear strength of
fiber-matrix interface
fiber strength in tension
• Why? Longer fibers carry stress more efficiently!Shorter, thicker fiber:
c
fd
15length fiber
Longer, thinner fiber:
Poorer fiber efficiency
Adapted from Fig. 16.7, Callister 7e.
c
f d
15length fiber
Better fiber efficiency
(x) (x)
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Composite Strength:Longitudinal Loading
Continuous fibers - Estimate fiber-reinforced composite
strength for long continuous fibers in a matrix
• Longitudinal deformation
c = mVm + fVf volume fraction but
e c = e m = e f isostrain
Ece = Em Vm + EfVf longitudinal (extensional)
modulus
mm
ff
m
f
VE
VE
F
F f = fiber
m = matrix
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Composite Strength:Transverse Loading
• In transverse loading the fibers carry less of the load - isostress
c = m = f = e c= e mVm + e fVf
f
f
m
m
ct E
V
E
V
E
1transverse modulus
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• Estimate of Ec and TS for discontinuous fibers:
-- valid when
-- Elastic modulus in fiber direction:
-- TS in fiber direction:
efficiency factor:-- aligned 1D: K = 1 (aligned )
-- aligned 1D: K = 0 (aligned )
-- random 2D: K = 3/8 (2D isotropy)-- random 3D: K = 1/5 (3D isotropy)
(aligned 1D)
Values from Table 16.3, Callister 7e. (Source for Table 16.3 is H. Krenchel, Fibre Reinforcement, Copenhagen: Akademisk Forlag, 1964.)
Composite Strength
c
f d
15length fiber
Particle-reinforced Fiber-reinforced Structural
(TS)c = (TS)mVm + (TS)fVf
Ec = EmVm + KEfVf
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Composite Production Methods-I
• Pultrusion– Continuous fibers pulled through resin tank, then
preforming die & oven to cure
Adapted from Fig. 16.13, Callister 7e.
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Composite Production Methods-II
• Filament Winding– Ex: pressure tanks
– Continuous filaments wound onto mandrel
Adapted from Fig. 16.15, Callister 7e. [Fig. 16.15 is from N. L. Hancox, (Editor), Fibre Composite Hybrid Materials, The Macmillan Company, New York, 1981.]
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. Comparison of the yield
strength of dispersion-strengthened sintered
aluminum powder (SAP) composite with that of two conventional two-phase
high-strength aluminum alloys. The composite has
benefits above about 300°C. A fiber-reinforced aluminum composite is
shown for comparison.
©2003 Brooks/C ole, a divis ion of Thomson Learning, Inc. Thomson Learning™is a trademark used herein under license.
A comparison of the specific modulus and specific strength of several composite materials with those of metals and polymers.
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• Stacked and bonded fiber-reinforced sheets
-- stacking sequence: e.g., 0º/90º-- benefit: balanced, in-plane stiffness
Adapted from Fig. 16.16, Callister 7e.
Composite Survey: Structural
Particle-reinforced Fiber-reinforced Structural
• Sandwich panels-- low density, honeycomb core-- benefit: small weight, large bending stiffness
honeycombadhesive layer
face sheet
Adapted from Fig. 16.18,Callister 7e. (Fig. 16.18 isfrom Engineered MaterialsHandbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)
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Hexagonal core
OxCore-over expanded in height coreFlexCore-exceptional formability
Composite Materials
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• CMCs: Increased toughness
Composite Benefits
fiber-reinf
un-reinf
particle-reinfForce
Bend displacement
• PMCs: Increased E/r
E(GPa)
G=3E/8K=E
Density, r [mg/m3].1 .3 1 3 10 30
.01
.1
1
10102
103
metal/ metal alloys
polymers
PMCs
ceramics
Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp. 139-146, 1984. Used with permission.
• MMCs:Increasedcreepresistance
20 30 50 100 20010 -10
10 -8
10 -6
10-4
6061 Al
6061 Al w/SiC whiskers
(MPa)
ess (s-1)
APPLICATIONS
Some Applications of Composite Materials Current Markets and Applications
Sources: SPI Composite Institute
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Rocket ARIANNE V
Static test in EMPA
Switzerland
Waterfront Structure and Decking Industry
Bridge decks
The Lion Gate Bridge,Vancouver, Canada
Highway Structure
Auto Skyway
Deck weight comparison per SF
Posts
Guard Rail
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FRP Composite Utility Poles
Pressure Vessel
Pipeline Infratructure
Pipes
Composite Turbine Blades for Wind Energy
Materials of Brake Pads
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Natural Fibers
Why Composites Inspection?
Much larger percentage of using composites in the world
Need to detect discontinuities that may lead to premature failure
Composites fail in catastrophically with little or no warning (different manner than metals)
Classifications of Inspections
Nondestructive Inspection- Visual- Ultrasonic- Infrared- Shearography- Thermography
Destructive Testing- Coupon Testing
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• Composites are classified according to:-- the matrix material (CMC, MMC, PMC)-- the reinforcement geometry (particles, fibers, layers).
• Composites enhance matrix properties:-- MMC: enhance y, TS, creep performance-- CMC: enhance Kc
-- PMC: enhance E, y, TS, creep performance• Particulate-reinforced:
-- Elastic modulus can be estimated.-- Properties are isotropic.
• Fiber-reinforced:-- Elastic modulus and TS can be estimated along fiber dir.-- Properties can be isotropic or anisotropic.
• Structural:-- Based on build-up of sandwiches in layered form.
• Applications and Inspections
Summary
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Sources:• Materials Science and Engineering: An Introduction
W.D. Callister, Jr., 8th edition, John Wiley and Sons, Inc.
(2010).
• Introduction to Materials Science for Engineers,
J.F. Shackelford, Prentice Hall International, Inc., (1996).
• The Science and Engineering of Materials, 4th ed
Donald R. Askeland – Pradeep P. Phulé (2007)
• Principles and Composite Material Mechanics,
Ronald F. Gibson, McGraw-Hill Inc., (1994).• Mechanics of Composite Materials,
Robert M. Jones, Taylor & Francis, (1999).
Thank You for
Your Attention