Course CodeCourse Code :: EBB 337EBB 337 Course TitleCourse Title :: Advanced Materials Advanced Materials

and Compositesand Composites Course UnitCourse Unit :: 33 Type of CourseType of Course :: CoreCore Name of academicsName of academics :: Dr. Mariatti JaafarDr. Mariatti Jaafar Dr. Ahmad Azmin Dr. Ahmad Azmin

MohamedMohamed Dr. Zuhailawati HussinDr. Zuhailawati Hussin (6) Contribution of Assessment:(6) Contribution of Assessment: 70% final 70% final

examination & 30% course work (15% Test and examination & 30% course work (15% Test and 15% Assignment/PBL)15% Assignment/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 2. To select and justify a suitable advanced composite materials for specific advanced composite materials for specific applicationsapplications

3. To propose a suitable fabrication 3. To propose a suitable fabrication technique of advanced composite technique of advanced composite materials for specific applicationsmaterials for 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 337 (Advanced EBB 337 (Advanced Materials & Composites)Materials & 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, F.L. Matthews, R.D. Rawlings, Composite Materials; Engineering & Composite Materials; Engineering & Science, Chapman & Hall, 1994.Science, Chapman & Hall, 1994.

R.P Sheldon, Composite Polymeric R.P Sheldon, Composite Polymeric Materials, Applied Science Publisher, Materials, Applied Science Publisher, 19821982

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

Test 1 – 16 Jan. 2009 (Friday)Test 1 – 16 Jan. 2009 (Friday) Short Assignment (not more than 5 pages;2 Short Assignment (not more than 5 pages;2

in a group)- due date 9 Jan. 2009in a group)- due date 9 Jan. 2009 Find an article from Journal on the following Find an article from Journal on the following

titles;titles; 1) Nanoparticles filled Polymer matrix composites for 1) Nanoparticles filled Polymer matrix composites for

food packaging applicationsfood packaging applications 2) Nanoparticles filled Polymer matrix composites for 2) Nanoparticles filled Polymer matrix composites for

electronic packaging applicationselectronic packaging applications 3) Natural fiber reinforced Polymer matrix composites 3) Natural fiber reinforced Polymer matrix composites

for construction or automotive applicationsfor construction or automotive applications 4) Synthetic fiber reinforced Polymer matrix 4) Synthetic fiber reinforced Polymer matrix

composites for aerospace applicationscomposites for aerospace applications 5) Particulate filler filled Polymer matrix composites 5) Particulate filler filled Polymer matrix composites

for medical applicationsfor medical applications

Short AssignmentShort Assignment

Summarize the followings;Summarize the followings; Materials used (what is the matrix, Materials used (what is the matrix,

reinforcement/filler, etc)reinforcement/filler, etc) Processing involved (hand lay-up, Processing involved (hand lay-up,

vacuum technique, injection molding, vacuum technique, injection molding, etc.)etc.)

Properties of composites measured, Properties of composites measured, relate the properties of composites relate the properties of composites compared to monolithic materialscompared to monolithic materials

Composites vs. monolithic Composites vs. monolithic materialsmaterials

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

Composite materials- a new emerging class of materials to overcome a current limits of monolithic of conventional materials

Constituents of composite Constituents of composite materialsmaterials

1. Matrix phaseContinuous phase, the primary phase. It holds the dispersed phase and shares a load with it.

2. Dispersed (reinforcing) phaseThe second phase (or phases) is imbedded in the matrix in a continuous/discontinuous form. Dispersed phase is usually stronger than the matrix, therefore it is sometimes called reinforcing phase.

3. InterfaceZone across which matrix and reinforcing phases interact (chemical, physical,mechanical)

Matrix: FunctionMatrix: Function

however the distribution of loads depends on the interfacial bondingshowever the distribution of loads depends on the interfacial bondings

Reinforcement: FunctionReinforcement: Function

Reinforcement: Function Reinforcement: Function depends on matrixdepends on matrix

Metal matrix: to increase the Metal matrix: to increase the hardness and creep resistance at hardness and creep resistance at high temp.high temp.

Polymer matrix: to improve Polymer matrix: to improve stiffness, strength and toughnessstiffness, strength and toughness

Ceramic matrix: to improve Ceramic matrix: to improve toughnesstoughness

Reinforcement can be in Reinforcement can be in the form of:the form of:

Continuous fiberContinuous fiber Organic fiber- i.e. Kevlar, polyethyleneOrganic fiber- i.e. Kevlar, polyethylene Inorganic fiber- i.e. glass, alumina, Inorganic fiber- i.e. glass, alumina,

carboncarbon Natural fiber- i.e. asbestos, jute, silkNatural fiber- i.e. asbestos, jute, silk

Short fiberShort fiber whiskerswhiskers ParticleParticle WireWire

Interface: FunctionInterface: Function

To transfer the stress from matrix to To transfer the stress from matrix to reinforcementreinforcement

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

Interfaces & InterphasesInterfaces & Interphases

Figure 1.2Figure 1.2

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

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

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

Widely used- ease of processing & lightweightWidely used- ease of processing & lightweight

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 (>1649ºC) & brittle(>1649ºC) & brittle

Used in aeronautics, military, etcUsed in aeronautics, military, etc Carbon and glass are common Carbon and glass are common

matrix used in CMCmatrix used in CMC

Natural CompositesNatural Composites WoodWood

Consists of Consists of cellulose, cellulose, hemiselulose & hemiselulose & ligninlignin

Cellulose- the Cellulose- the strongest strongest component, 65% component, 65% unidirectional unidirectional alignmentalignment

Lignin behave as Lignin behave as adhesive, tighten adhesive, tighten the wood the wood componentscomponents

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 ere is an example of a vaulting pole

made from glass fibre reinforced polymer made from glass fibre reinforced polymer (GFRP) composites and carbon fibre (GFRP) composites and carbon fibre

reinforced polymer (CFRP) compositesreinforced polymer (CFRP) composites

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

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

Many end-applicationsMany end-applications

Properties of composites Properties of composites depend on depend on

Amount of phaseAmount of phase- Amount/proportion (can be expressed - Amount/proportion (can be expressed

in weight fraction (Wf) or volume in weight fraction (Wf) or volume fraction (Vf))of phases strongly fraction (Vf))of phases strongly influence the properties of composite influence the properties of composite materials. materials.

XXcc = X = Xff V Vff + X + Xmm (1 - V (1 - Vff ) - ) - Rule of MixtureRule of Mixture

XXcc = Properties of composites = Properties of composites

XXf f = Properties of fiber= Properties of fiber

XXmm= Properties of matrix= Properties of matrix

VoidsVoids

Free volumeFree volume Gas emission leads to voids in Gas emission leads to voids in

the final productthe final product In composites- Voids exist in the In composites- Voids exist in the

matrix, interface and in between matrix, interface and in between fiber & fiberfiber & fiber

Voids create stress Voids create stress concentration points- influence concentration points- influence the properties of the compositesthe properties of the composites

Geometry of dispersed Geometry of dispersed phase (particle size, phase (particle size,

distribution, orientation) distribution, orientation) Shape of dispersed phase (particle- Shape of dispersed phase (particle-

spherical or irregular, flaky, whiskers, spherical or irregular, flaky, whiskers, etc)etc)

Particle/fiber size ( fiber- short, long, Particle/fiber size ( fiber- short, long, continuous); particle (nano or micron size)continuous); particle (nano or micron size)

Orientation of fiber/particle (unidirection, Orientation of fiber/particle (unidirection, bi-directions, many directions)- influence bi-directions, many directions)- influence isotropic dan an-isotropic propertiesisotropic dan an-isotropic properties

Dictribution of dispersed phase Dictribution of dispersed phase (homogenus/uniform, inhomogenus)(homogenus/uniform, inhomogenus)

Examples of different Examples of different composite geometrical composite geometrical

arrangementsarrangements

Processing technique and Processing technique and parametersparameters

Influence final product, selection of Influence final product, selection of correct raw materials, void content, correct raw materials, void content, etcetc