• Course CodeCourse Code :: EBB 324EBB 324• Course TitleCourse Title :: Advanced Materials Advanced Materials

and Compositesand Composites• Course UnitCourse Unit :: 44• Type of CourseType of Course :: CoreCore• Name of academicsName of academics ::Dr. Mariatti JaafarDr. Mariatti Jaafar• Dr. Hazizan Md AkilDr. Hazizan Md Akil• Dr. Zuhailawati Dr. Zuhailawati

HussinHussin• (6) Contribution of Assessment:(6) Contribution of Assessment:70% final 70% final

examination & 30% course work (15% Test examination & 30% course work (15% Test and 15% Quiz/PBL)and 15% Quiz/PBL)

Course Objectives/Course Course Objectives/Course Outcomes (CO)Outcomes (CO)

• 1. To classify different types of advanced 1. To classify different types of advanced composite materialscomposite materials

• 2. To select and justify a suitable advanced 2. To select and justify a suitable advanced composite materials for specific applicationscomposite materials for specific applications

• 3. To propose a suitable fabrication 3. To propose a suitable fabrication technique of advanced composite materials technique of advanced composite materials for specific applicationsfor specific applications

• 4. To apply suitable theory to estimate the 4. To apply suitable theory to estimate the properties of the advanced composite properties of the advanced composite materialsmaterials

EBB 324 (Advanced Materials EBB 324 (Advanced Materials & Composites)& Composites)

Topic Contents

Introduction to composite materials(Definition and classification of composite materials,

natural composites, the benefit of composites)

Introduction to composite materials(Types of matrix (natural and synthetic), types of

reinforcement (natural and synthetic), factors which determine properties)

Reinforcement-matrix interface(Wettability, Interfacial bonding, methods to measure

bond strength)

Polymer matrix composites(Introduction, types of polymer matrices

(thermoplastics, thermoset & rubber), processing of PMC- Hand lay-up, spray-up moulding methods (match die moulding, bag moulding method, vacuum bagging, pressure bagging, RTM), pultrusion, filament winding)

Polymer matrix composites(Some commercial PMCs- epoxy and polyester matrix

composites, PEEK matrix composites, rubber matrix composites, etc.)

ReferencesReferences

• R.F. Gibson, Principles of Composite R.F. Gibson, Principles of Composite Materials Mechanics, McGraw Hill, Inc, Materials Mechanics, McGraw Hill, Inc, 1994.1994.

• F.L. Matthews, R.D. Rawlings, Composite F.L. Matthews, R.D. Rawlings, Composite Materials; Engineering & Science, Materials; Engineering & Science, Chapman & Hall, 1994.Chapman & Hall, 1994.

• R.P Sheldon, Composite Polymeric R.P Sheldon, Composite Polymeric Materials, Applied Science Publisher, 1982Materials, Applied Science Publisher, 1982

• S. C. Sharma, Composite Materials, S. C. Sharma, Composite Materials, Narosa Publishing House, 2000Narosa Publishing House, 2000

What is Composites?What is Composites?

• Combination of 2 or more materialsCombination of 2 or more materials• Each of the materials must exist Each of the materials must exist

more than 5%more than 5%• Presence of interphasePresence of interphase• The properties shown by the The properties shown by the

composite materials are differed composite materials are differed from the initial materialsfrom the initial materials

• Can be produced by various Can be produced by various processing techniquesprocessing techniques

Classifications of Classifications of compositescomposites

• Matrix; PMC, MMC, CMCMatrix; PMC, MMC, CMC

• Function; electrical & structureFunction; electrical & structure

• Geometry of reinforcements; fiber Geometry of reinforcements; fiber composites & particulate compositescomposites & particulate composites

Classification based on Classification based on Geometry of reinforcementGeometry of reinforcement

Composite materials

Fiber-composites

Particulate-

composites

Random

orientation

Uni

-directionalRandom

orientation

Uni-

directional

Two-

directional

WhiskersFlak

e

Examples of compositesExamples of composites

a) Particulate & randomb) Discontinuous fibers & unidirectionalc) Discontinuous fibers & randomd) Continuous fibers & unidirectional

Classification based on Classification based on MatricesMatrices

Composite materials

Matrices

Polymer Matrix Composites

(PMC)

Metal Matrix Composites

MMC)

Ceramic Matrix Composites

(CMC)

Thermoset Thermoplastic

Rubber

Polymer matrix compositesPolymer matrix composites

• Widely used- ease of processing, Widely used- ease of processing, lightweight & desirable mechanical lightweight & desirable mechanical propertiesproperties

Metal Matrix Composites Metal Matrix Composites (MMC)(MMC)• Generate wide interest in researchGenerate wide interest in research• Not as widely use as PMCNot as widely use as PMC• Higher strength, stiffness & fracture Higher strength, stiffness & fracture

toughnesstoughness• Can withstand elevated temperature Can withstand elevated temperature

in corrosive environment than PMCin corrosive environment than PMC• Most metal and alloy can be used as Most metal and alloy can be used as

matricesmatrices

Ceramic Matrix Composites Ceramic Matrix Composites (CMC)(CMC)

• Able to withstand high temperature Able to withstand high temperature (>1649(>1649ºC) ºC) & brittle& brittle

• Used in aeronautics, military, etcUsed in aeronautics, military, etc

• Carbon and glass are common matrix Carbon and glass are common matrix used in CMCused in CMC

Natural CompositesNatural Composites

• WoodWood– Consists of cellulose, hemiselulose & Consists of cellulose, hemiselulose &

ligninlignin– Cellulose- the strongest component, Cellulose- the strongest component,

65% unidirectional alignment65% unidirectional alignment– Lignin behave as adhesive, tighten the Lignin behave as adhesive, tighten the

wood componentswood components

• BoneBone– Example; hydroxyapatite reinforced Example; hydroxyapatite reinforced

collagen compositescollagen composites

Natural CompositesNatural Composites

Pole (Construction Pole (Construction Industry)Industry)

• Traditional Traditional woodwood→steel→concrete→poly→steel→concrete→polymer composite (mer composite (made of made of layers of glass fabric + resins)layers of glass fabric + resins)

• Advantages of Polymer Advantages of Polymer CompositesComposites

1) won't rust, or corrode1) won't rust, or corrode

2)require no preservatives2)require no preservatives

3) light-weight, lighter than 3) light-weight, lighter than aluminum, wood, steel or aluminum, wood, steel or concrete. concrete.

4) the lowest possible total 4) the lowest possible total installed costinstalled cost

Modern vaulting polesModern vaulting polesHHere is an example of a vaulting pole made ere is an example of a vaulting pole made from glass fibre reinforced polymer (GFRP) from glass fibre reinforced polymer (GFRP) composites and carbon fibre reinforced composites and carbon fibre reinforced polymer (CFRP) compositespolymer (CFRP) composites

Benefits of Composites???Benefits of Composites???

• Improved properties (thermal, Improved properties (thermal, mechanical, electrical, etc)mechanical, electrical, etc)

• Many end-applicationsMany end-applications

Bahan pembentuk kompositBahan pembentuk komposit

• MatriksMatriks

• Bahan tetulang/penguat Bahan tetulang/penguat (Reinforcement)(Reinforcement)

• Antaramuka/antarafasaAntaramuka/antarafasa

Matriks: FungsiMatriks: Fungsi

• Mengikat bahan tetulangMengikat bahan tetulang

• Memindah dan mengagihkan beban Memindah dan mengagihkan beban kenaan kepada tetulang, ttp kenaan kepada tetulang, ttp pemindahan beban bergantung pemindahan beban bergantung kepada ikatan antaramuka kepada ikatan antaramuka

MatriksMatriks

• Needs to withstand temperature Needs to withstand temperature variationsvariations

• Offer weight advantages, ease of Offer weight advantages, ease of handlinghandling

Bahan tetulang: Fungsi Bahan tetulang: Fungsi bergantung kepada matriksbergantung kepada matriks

• matriks logam: utk meningkatkan matriks logam: utk meningkatkan kekerasan dan ketahanan rayapan kekerasan dan ketahanan rayapan suhu tinggisuhu tinggi

• matriks polimer: utk memperbaiki matriks polimer: utk memperbaiki sifat kekakuan, kekuatan dan sifat kekakuan, kekuatan dan keliatankeliatan

• matriks seramik: utk memperbaiki matriks seramik: utk memperbaiki keliatankeliatan

Bahan tetulang wujud dalam Bahan tetulang wujud dalam bentuk:bentuk:• Gentian selanjarGentian selanjar

– Gentian organik- cthnya Kevlar, Gentian organik- cthnya Kevlar, polietilenapolietilena

– Gentian tak organik- cthnya kaca, Gentian tak organik- cthnya kaca, alumina, karbonalumina, karbon

– Gentian asli- cthnya asbestos, jut, suteraGentian asli- cthnya asbestos, jut, sutera

• Gentian pendekGentian pendek

• Hablur sesunggut (whiskers)Hablur sesunggut (whiskers)

• PartikelPartikel

• DawaiDawai

Antarafasa: FungsiAntarafasa: Fungsi

• Memindahkan tegasan daripada Memindahkan tegasan daripada matriks kepada bahan tetulangmatriks kepada bahan tetulang

Sometimes surface treatment is Sometimes surface treatment is carried out to achieve the required carried out to achieve the required bonding to the matrixbonding to the matrix

Types of matrix (natural and Types of matrix (natural and synthetic)synthetic)

• NaturalNatural– Silica sand, limestone (CaCO3), talc, etcSilica sand, limestone (CaCO3), talc, etc– Starch, epoxy based on soy bean, Starch, epoxy based on soy bean,

chitosan, etcchitosan, etc

• SyntheticSynthetic– Fumed silica, fused silica, glass, etcFumed silica, fused silica, glass, etc– Epoxy, polyester, PP, PE, etcEpoxy, polyester, PP, PE, etc

Types of reinforcement Types of reinforcement (natural and synthetic)(natural and synthetic)

• NaturalNatural– Silica sand, limestone (CaCO3), talc, etcSilica sand, limestone (CaCO3), talc, etc– Natural fibers, wood, etcNatural fibers, wood, etc

• SyntheticSynthetic– Glass fiber, boron fibers, etcGlass fiber, boron fibers, etc– Fumed silica, fused silica, glass, etcFumed silica, fused silica, glass, etc

Faktor-faktor yang mengawal Faktor-faktor yang mengawal sifat-sifat kompositsifat-sifat komposit

• Komposisi komponenKomposisi komponen• -Komposisi setiap komponen -Komposisi setiap komponen

(matriks dan tetulang) (matriks dan tetulang) mempengaruhi terus sifat2 akhir mempengaruhi terus sifat2 akhir komposit. komposit.

• XXcc = X = Xff V Vff + X + Xmm (1 - V (1 - Vff ) – ) – Hukum Hukum Pencampuran/Rule of MixturePencampuran/Rule of Mixture

• XXcc = Sifat komposit = Sifat komposit• XXf f = Sifat gentian= Sifat gentian• XXmm= Sifat matriks= Sifat matriks

RonggaRongga

•ruang udara yang terkumpul atau ruang udara yang terkumpul atau terperangkap dalam kompositterperangkap dalam komposit

•dalam komposit, rongga wujud dalam komposit, rongga wujud dalam matriks, antaramuka dan dalam matriks, antaramuka dan antara gentian-gentianantara gentian-gentian

•kehadiran rongga dalam struktur kehadiran rongga dalam struktur komposit menyebabkan wujudnya komposit menyebabkan wujudnya titik pemusatan tegasan- titik pemusatan tegasan- menjejaskan sifat-sifat akhir menjejaskan sifat-sifat akhir kompositkomposit

•ruang udara yang terkumpul atau ruang udara yang terkumpul atau terperangkap dalam kompositterperangkap dalam komposit

•dalam komposit, rongga wujud dalam komposit, rongga wujud dalam matriks, antaramuka dan dalam matriks, antaramuka dan antara gentian-gentianantara gentian-gentian

•kehadiran rongga dalam struktur kehadiran rongga dalam struktur komposit menyebabkan wujudnya komposit menyebabkan wujudnya titik pemusatan tegasan- titik pemusatan tegasan- menjejaskan sifat-sifat akhir menjejaskan sifat-sifat akhir kompositkomposit

Bentuk, saiz, orientasi dan Bentuk, saiz, orientasi dan taburan gentiantaburan gentian

• Bentuk gentian (partikel- bulat, Bentuk gentian (partikel- bulat, whiskers, bersudut, etc)whiskers, bersudut, etc)

• Saiz gentian ( pendek, panjang, Saiz gentian ( pendek, panjang, selanjar)selanjar)

• Orientasi gentian (satu arah, dua arah, Orientasi gentian (satu arah, dua arah, pelbagai arah)- mempengaruhi sifat pelbagai arah)- mempengaruhi sifat isotropi dan tak isotropiisotropi dan tak isotropi

• Taburan gentian (homogenus/uniform, Taburan gentian (homogenus/uniform, takhomogenus)takhomogenus)

Examples of different Examples of different composite geometrical composite geometrical arrangementsarrangements

Teknik dan parameter Teknik dan parameter pemprosesanpemprosesan

• mempengaruhi pemilihan bahan mempengaruhi pemilihan bahan mentah yang sesuai, bentuk akhir mentah yang sesuai, bentuk akhir komposit, kandungan rongga dllkomposit, kandungan rongga dll

• mempengaruhi struktur dan mempengaruhi struktur dan morfologi sesuatu komposit morfologi sesuatu komposit

Antaramuka & AntarafasaAntaramuka & Antarafasa(Interfaces & Interphases)(Interfaces & Interphases)

• Figure 1.2Figure 1.2

Apabila Antarafasa wujud, terdapat 2 Apabila Antarafasa wujud, terdapat 2 antaramuka yang hadirantaramuka yang hadir