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Copyright Carl Zweben 2010 Slide 1
INTRODUCTION TO COMPOSITE MATERIALS
Carl Zweben, PhD Life Fellow ASME
Fellow SAMPE and ASMAssociate Fellow, AIAA
Composites & Thermal Materials Consultant 62 Arlington Road
Devon, PA 19333-1538 Phone: 610-688-1772
E-mail: c.h.zweben@usa.nethttp://sites.google.com/site/zwebenconsulting
Copyright Carl Zweben 2010 Slide 2
The information in these slides is part of a short course on composite materials that is presented
publicly and in-house
Contact author for information
Copyright Carl Zweben 2010 Slide 3
OUTLINE
• Introduction• Key fibers and composites• Status of PMCs, MMCs, CAMCs, CMCs• Applications• Appendix
Copyright Carl Zweben 2010 Slide 4
INTRODUCTION
Copyright Carl Zweben 2010 Slide 5
COMPOSITE MATERIAL
1. Two or more materials bonded together (Anthony Kelly)– Distinguishes composites from alloys
2. A material consisting of any combination of fibers, whiskers and particles in a common matrix
Copyright Carl Zweben 2010 Slide 6
WHY COMPOSITES?
• High specific strength (strength/density)• High specific modulus (modulus/density)• Fatigue resistance• Creep and creep rupture resistance• Low, tailorable coefficient of thermal expansion• High temperature capability • Wear resistance• Corrosion resistance• Tailorable electrical conductivity
– Very low to very high
Copyright Carl Zweben 2010 Slide 7
WHY COMPOSITES? (continued)
• Tailorable thermal conductivity – very low to extremely high
• Tailorable mechanical and thermal properties• Unique combinations of properties• Great design flexibility• Formable to complex shapes• Low cost (some)• Enabling technology for many applications, e.g.
– Lightweight vehicle and aerospace structures– High-performance thermal management– Lightweight optical systems– Infrastructure repair
Copyright Carl Zweben 2010 Slide 8
DESIGN FLEXIBILITY
Copyright Carl Zweben 2010 Slide 9
CLASSES OF COMPOSITE MATERIALS
MATRIX
REINFORCEMENTPolymer Metal Ceramic Carbon
Polymer X X X XMetal X X X X
Ceramic X X X XCarbon X X X X
Polymer Matrix Composites (PMCs)Metal Matrix Composites (CMCs)Ceramic Matrix Composite (CMC)
Carbon Matrix Composites (CAMCs)Carbon/Carbon Composites (CCCs)
Copyright Carl Zweben 2010 Slide 10
REINFORCEMENTS
Continuous Fibers
Particles
Discontinuous Fibers, Whiskers
Fabrics, Braids, etc.
Copyright Carl Zweben 2010 Slide 11
TERMINOLOGY
• Advanced composite: composite with properties superior to those of glass fiber-reinforced polymer (GFRP)
• Specific property– Absolute property divided by density (or
specific gravity, which is dimensionless)
Copyright Carl Zweben 2010 Slide 12
BRIEF HISTORY OF COMPOSITES
• Straw--reinforced mud cited in Old Testament– Organic fiber-reinforced CMC
• GFRP well established by 1950s• R&D on advanced composites: CCCs, PMCs,
MMCs and CMCs started 1960s-1970s• Carbon fiber-reinforced polymers (CFRPs)
became dominant advanced composites in 1970s• CCCs established for thermal protection ~ 1970s• MMCs used in specialty applications
– Automobile engines– Electronics thermal management
Copyright Carl Zweben 2010 Slide 13
BRIEF HISTORY OF COMPOSITES (continued)
• CMCs used in specialty applications• GFRP most widely used composite, by far• CFRP dominates high-performance applications• Composites now baseline in numerous aerospace
and commercial applications• Industrial applications now largest sector
– Everything except aerospace and sports– Wind turbine blades, infrastructure, etc.
Copyright Carl Zweben 2010 Slide 14
COMMON TYPES OF LAMINATESCOMMON TYPES OF LAMINATES
Copyright Carl Zweben 2010 Slide 15
KEY FIBERS AND COMPOSITES
Copyright Carl Zweben 2010 Slide 16
KEY FIBERS
• Glass– E-glass most widely used fiber by orders of
magnitude– Others: high-strength, chemical-resistant
• Carbon– Workhorse high-performance fibers– Many types: polyacrylonitrile (PAN), pitch,
CVD, etc.)• Boron• Silicon carbide-based• Alumina-based
Copyright Carl Zweben 2010 Slide 17
KEY FIBERS (continued)
• High-modulus synthetic organics– Aramid (aromatic polyamide)– High density polyethylene– PBO– M5 PIPD
• Natural organic fibers, e.g.• Flax, jute, hemp and kenaf, wood, etc.
• Basalt
Copyright Carl Zweben 2010 Slide 18
CARBON FIBER IMPROVEMENTS 1965 - 2005
1965** 2005Max modulus, GPa (MSI) 380 (55) 965 (140)Max tens str, GPa (KSI) 2.3 (330) 6.9 (1000)No. of PAN-based fibers 3 DozensNo. of pitch-based fibers 0 ManyMax therm cond, W/m.K 30 2000Max fiber length 1m ContinuousMinimum cost $2000/Kg $16/Kg
** Carbon fibers were experimental in 1965
Copyright Carl Zweben 2010 Slide 19
ELECTRICAL AND THERMAL CONDUCTIVITY
Copyright Carl Zweben 2010 Slide 20
SPECIFIC TENSILE STRENGTH vs SPECIFIC MODULUS (Tensile strength/density vs. Modulus/density)
0 100 200 3000
1000
2000
2500
1500
500
Specific Modulus (MPa)
Spec
ific
Tens
ile S
tren
gth
(GPa
)UHS PAN C/Ep
SM PAN C/Ep
SiCp /AlBe
Boron/EpUHM PAN C/Ep
UHM Pitch C/Ep
E-Glass/EpAluminum, Steel,
Titanium, Magnesium
Aramid/Ep
UnidirectionalQuasi-Isotropic
Copyright Carl Zweben 2010 Slide 21
MAXIMUM USE TEMPERATURE vs. DENSITY
Copyright Carl Zweben 2010 Slide 22
CONTINUOUS FIBERS MAKE CERAMICS AND CARBON USEFUL STRUCTURAL MATERIALS
Copyright Carl Zweben 2010 Slide 23
0 20 40 60 80 100
PARTICLE VOLUME FRACTION (%)
CO
EFFI
CIE
NT
OF
THER
MA
L EX
PAN
SIO
N (p
p m/K
)
25
20
15
10
5
0
Aluminum
Copper
Beryllium
Titanium, SteelAluminaSilicon
Powder MetallurgyInfiltration
CTE OF SILICON-CARBIDE-PARTICLE-REINFORCED ALUMINUM (Al/SiC) vs PARTICLE VOLUME FRACTION
E-glass PCB
NEW MATERIAL
Copyright Carl Zweben 2010 Slide 24
Silver
Copper
Aluminum
E-glass PCB
SiC/Al (Al/SiC)
C/Al
C/Cu
C/C
C/Ep
Cu/W
Kovar
Si, GaAs, Silica, Alumina, Beryllia, Aluminum Nitride, LTCC
Si-Al
Diamond-Particle-Reinforced Metals and Ceramics
SiC/Cu
HO
PG
(170
0)
-5 0 5 10 15 20 25COEFFICIENT OF THERMAL EXPANSION (ppm/K)
THER
MA
L C
ON
DU
CTI
VITY
(W/m
K)
100
200
300
400
500
600
0 Invar
THERMAL CONDUCTIVITY vs CTE FOR PACKAGING MATERIALS
1200
Copyright Carl Zweben 2010 Slide 25
APPLICATIONS
Copyright Carl Zweben 2010 Slide 26
STATUS OF COMPOSITES
• PMCs workhorse materials for structures– Wide range of commercial and aerospace
applications– E-glass and carbon key fibers– Thermosets key resins– Increasing use of thermoplastics– Natural fibers in automotive secondary parts– Nanoclay/thermoplastics in automobiles
• Carbon matrix composites– CCCs well established for thermal protection– SiC/carbon in aircraft engine parts
Copyright Carl Zweben 2010 Slide 27
STATUS OF COMPOSITES (cont.)
• CMCs– Challenging CAMCs– Limited, but significant use
• MMCs– Cermets (ceramic/metal) widely used
• E.g. “tungsten carbide” cutting tools– Used in Honda and Toyota auto engines– Limited use of fiber- and particle-reinforced
materials in structures and machine parts– Transmission lines in early production– Widely used in electronic packaging
Copyright Carl Zweben 2010 Slide 28
KEY ADVANCED COMPOSITES APPLICATIONS
• Aerospace & defense structures– Aircraft– Spacecraft– Missiles and launch vehicles– Ships– Optical systems
• Aircraft engines• Sports equipment• Natural gas vehicle fuel tanks• Wind turbine blades
Copyright Carl Zweben 2010 Slide 29
KEY ADVANCED COMPOSITES APPLICATIONS (cont)
• Infrastructure• Biomedical equipment• Precision machinery• Oil exploration and production• Automobile engines• High-end automobile structures and brakes• Machinery• Electronics and photonics thermal management
Copyright Carl Zweben 2010 Slide 30
COMPOSITES ARE THE MATERIALS OF THE HERE AND NOW
Copyright Carl Zweben 2010 Slide 31
APPENDIX 1 PROPERTIES OF SELECTED
COMPOSITE MATERIALS
Copyright Carl Zweben 2010 Slide 32
PROPERTIES OF SELECTED COMPOSITES
• Thousands of different materials in production• Polymer matrix composites• Metal matrix composites• Carbon matrix composites
– Carbon/carbon composites• Ceramic matrix composites
Copyright Carl Zweben 2010 Slide 33
PROPERTIES OF UNIDIRECTIONAL ULTRAHIGH- STRENGTH PAN CARBON/ POLYMER
Axial extensional modulus = 25 MSI (170 GPa)Transverse extensional modulus = 1.5 MSI (10 GPa)Axial shear modulus = 0.6 MSI (4.1 GPa)Axial Poisson’s ratio = 0.25Axial tensile strength = 510 KSI (3530 MPa)Transverse tensile strength = 6 KSI (41 MPa)Axial compression strength = 200 KSI (1380 MPa)Transverse compression strength = 25 KSI (170 MPa)Axial CTE = 0.3 PPM/F (0.5 PPM/K)Transverse CTE = 15 PPM/F (27 PPM/K)Axial Thermal Conductivity = 6 BTU/h-ft-F (10 W/mK)Transverse Thermal Cond = 0.3 BTU/h-ft-F (0.5 W/mK)Density = 0.058 PCI (1.61g/cm3)
Copyright Carl Zweben 2010 Slide 34
PROPERTIES OF QUASI-ISOTROPIC ULTRAHIGH- STRENGTH PAN CARBON/ POLYMER
Extensional modulus = 9.1 MSI (63 GPa)Shear modulus = 3 MSI (21 GPa)Poisson’s ratio = 0.32Tensile strength = 200 KSI (1350 MPa)Compression strength = 84 KSI (580 MPa)Inplane CTE = 1.3 PPM/F (2.3 PPM/K)Inplane thermal cond = 3 BTU/h-ft-F (6 W/mK)Density = 0.058 PCI (1.61 g/cm3)
Copyright Carl Zweben 2010 Slide 35
PROPERTIES OF UNIDIRECTIONAL ULTRAHIGH- MODULUS PITCH CARBON/POLYMER
Axial extensional modulus = 70 MSI (480 GPa)Transverse extensional modulus = 1.5 MSI (10 GPa)Axial shear modulus = 0.6 MSI (4.1 GPa)Axial Poisson’s ratio = 0.25Axial tensile strength = 130 KSI (900 MPa)Transverse tensile strength = 3 KSI (20 MPa)Axial compression strength = 40 KSI (280 MPa)Transverse compression strength = 15 KSI (100 MPa)Inplane shear strength = 6 KSI (41 MPa)Axial CTE = - 0.6 PPM/F (-1.1 PPM/K)Transverse CTE = 15 PPM/F (27 PPM/K)Axial Thermal Conductivity = 380 BTU/h-ft-F (660 W/mK)Transverse Thermal Cond = 6 BTU/h-ft-F (10 W/mK)Density = 0.065 PCI (1.8 g/cm3)
Copyright Carl Zweben 2010 Slide 36
PROPERTIES OF QUASI-ISOTROPIC ULTRAHIGH MODULUS PITCH CARBON/ POLYMER
Extensional modulus = 24 MSI (165 GPa)Shear modulus = 9.2 MSI (9.2 GPa)Poisson’s ratio = 0.32Tensile strength = 45 KSI (310 MPa)Compression strength = 14 KSI (96 MPa)Inplane CTE = - 0.2 PPM/F (-0.4 PPM/K)Inplane therm cond = 195 BTU/h-ft-F (335 W/mK)Density = 0.065 PCI (1.80 g/cm3)
Copyright Carl Zweben 2010 Slide 37
PROPERTIES OF SELECTED UNIDIRECTIONAL MMCs
Fiber Matrix Density Axial Trans Axial Trans Axial g/cm3 Mod Mod Tens Tens Comp
GPa GPa Str Str Str (Msi) (Msi) MPa MPa MPa
(Msi) (Ksi) (Ksi)
UHM Carb Al 2.4 450 15 690 15 340(pitch) (65) (5) (100) (5) (50)
Boron Al 2.6 210 140 1240 140 1720(30) (20) (180) (20) (250)
Alumina Al 3.2 240 130 1700 120 1800(35) (19) (250) (17) (260)
SiC Ti 3.6 260 170 1700 340 2760 (38) (25) (250) (50) (400)
Copyright Carl Zweben 2010 Slide 38
PROPERTIES OF ALUMINUM, TITANIUM AND SILICON CARBIDE-PARTICLE REINFORCED ALUMINUM
Aluminum Titanium Composite(6061-T6) (6Al-4V) Particle Vf (%)
Property 25 55 70Modulus, GPa 69 100 114 186 265Tens yield, MPa 275 1000 400 495 -Tens Ult, Mpa 310 1100 485 530 225Elongation, % 15 5 3.8 0.6 0.1Cond, W/m-K 180 6.7 ~200 ~200 ~200CTE, PPM/K 23 9 16.4 10.4 6.2 Density (g/cm3) 2.77 4.43 2.88 2.96 3.00
Copyright Carl Zweben 2010 Slide 39
TITANIUM CARBIDE PARTICLE-REINFORCED STEEL (“FERRO-TIC”)
Tool Steel “Ferro-TiC”Density, g/cm3 7.9 6.60Elastic modulus, GPa 200 290Modulus/density, GPa 25 44Tensile strength, GPa 0.6-2.0 1.5Comp strength, GPa - 3.6
Source: Alloy Technology
Copyright Carl Zweben 2010 Slide 40
ULTRAHIGH-THERMAL-CONDUCTIVITY MATERIALS
k CTE Specific k/SGMATERIAL (W/m-K) (ppm/K) Gravity (W/m-K)Copper 400 17 8.9 45Diamond/Al 325-600 7-9 3-4 93-171Diamond/Cu 400-1200 5-7.7.7 5.5-7 62-185Diamond/Co >600 3.0 4.1 >146Diamond/Ag 550-650 5-8 6-7 85-100Diamond/SiC 600-680 1.8 3.3 182-206---------------------------------------------------------------------------------------Diamond/Si 525 4.5 - -Diamond/Mg 575 5.5 - -Diamond+SiC/Al 575 5 - -
Materials below line are experimental
Copyright Carl Zweben 2010 Slide 41
MECHANICAL PROPERTIES OF 2D ACC-4 ADVANCED CARBON/CARBON (0/90)
PROPERTYTensile modulus 103 GPa 15 MsiCompression modulus 103 GPa 15 MsiInplane shear modulus 17 GPa 2.5 MsiInterlaminar tensile modulus 10 GPa 1.5 MsiTensile strength 276 MPa 40 KsiCompression strength 165 MPa 24 KsiInplane shear strength 41 MPa 2.5 KsiInterlaminar shear strength 10 MPa 1.5 KsiInterlaminar tensile strength 10 MPa 0.9 Ksi
Source: H.G. Maahs, “Carbon-Carbon Composites”, Flight Vehicle Materials, Structures and Dynamics, vol. 3, ASME, New York, 1992
Copyright Carl Zweben 2010 Slide 42
PROPERTIES OF ENHANCED SiC/SiC
Reinforcement: CG “Nicalon” plain weave fabricProcess: chemical vapor infiltrationProprietary materials added to matrix to protect fibersDensity: 2.30 g/cm3 (0.083 lb/in3)Axial tensile modulus, GPa (Msi): 140 (20)Inplane shear modulus, GPa (Ksi) : 70 (10)Tensile strength, MPa (Ksi): 225 (33)Compressive strength, MPa (Ksi): 500 (73)Inplane shear strength MPa, (Ksi) : 180 (26)Through-thickness tensile strength, MPa (Ksi): >13 (>1.9)Interlam. shear strength, MPa (Ksi): 30 (4.3)
Source: AlliedSignal/Honeywell Advanced Composites/GE Power Systems
Copyright Carl Zweben 2010 Slide 43
APPENDIX 2 ABBREVIATIONS AND TERMINOLOGY
Copyright Carl Zweben 2010 Slide 44
TERMINOLOGY
• Homogeneous– Properties constant throughout material
• Heterogeneous– Properties vary throughout material– E.g. different in matrix and reinforcement– Composites always heterogeneous
• Isotropic– Properties the same in every direction– Particulate composites can be isotropic
Copyright Carl Zweben 2010 Slide 45
TERMINOLOGY (continued)
• Anisotropic– Properties vary with direction– Fiber-reinforced materials typically anisotropic– May be inplane isotropic (transversely
isotropic)• Specific property
– Absolute property divided by density (or specific gravity, which is dimensionless)
Copyright Carl Zweben 2010 Slide 46
KEY ABBREVIATIONS• PMC: polymer matrix composite• CMC: ceramic matrix composite• MMC: metal matrix composite• CAMC: carbon matrix composite• CCC: carbon/carbon composite• CFRP: carbon fiber-reinforced polymer• GFRP: glass fiber-reinforced polymer• AFRP: aramid fiber-reinforced polymer• C: carbon• CNT: carbon nanotube• PAN: polyacrylonitrile• Ep: epoxy• BMI: bismaleimide• PI: polyimide• DRA: discontinuously reinforced aluminum USAF
– SiC particle-reinforced aluminum– Called Al/SiC in electronic packaging industry
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