Composite Materials - Research Options

8/8/2019 Composite Materials - Research Options

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COMPOSITE MATERIALS

RESEARCH OPTIONS

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Definition

Composite materials ar eenginee red ma te rials ma de f rom two or moreconstituent ma te rials with significa ntly diffe rent ph ys ical or chemical prope rties whichrema in sep ara te a nd di stinct on a ma croscopicleve l within the finished structure.

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S ince . . .

Natural compositeW ood cellulose fibe rs in a ma trix of lignin

Primitive manmade composite materialsS tra w a nd mud combined to fo rm b ricks for building construction.

Visi b le applicationsS tee l a nd a gg reg a te reinforced po r tla nd cement or as phal tconcrete .

More closest personalS hower stalls a nd b a th tubs ma de of fibe rg lass .Imita tion gra nite a nd cultured m ar b le sinks a nd counte r top s .

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H ow ar e the y ma de ?

Ma de up of individu al ma te rials refe rr ed to as constituent ma te rials .At leas t one po rtion of e a ch type i s requi redMatrix

Ma trix ma te rial surrounds a nd suppo rts the reinforcement ma te rials by ma inta ining their re la tive po sitions.

Reinforcement.The reinforcements impar t their special mecha nical a nd phys ical p rope r ties to enha nce the ma trix prope rties.

Synergism

P roduces ma te rial p rope r ties una va ila b le f rom the individual constituentma te rials W ide var iety of ma trix a nd strengthening m a te rials all ows the de signer of the p roduct o r structure to choo se a n optimum combina tion.

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Resear ch Options . . .

Molding Method sP rope rties

Impa ct onP

roe r tiesResinsFa ilureTestingMa te rials

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Moulding method

Vacuum b ag mouldingsPressure b ag mouldingAutoclave mouldingResin transfer moulding (RTM)

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Vacuum bag mouldings

A process using a two-sided mou ld set tha t sha pe s bothsurfa ces of the p a nel.Lower side - rigid mould

Uppe r side - a flexib le memb ra ne o r va cuum ba g.Flexib le memb ra ne ca n be a reusa b le silicone ma terial or a n ext ruded po lymer film.

Then, va cuum is a pp lied to the mou ld ca vity.P rocess ca n be pe rformed a t eithe r a mbient o r e leva ted tempe ra ture with a mbient a tmosphe ricpressure a cting upon the v a cuum ba g. Most economical way is using a venturi va cuuma nd a ir compressor or a va cuum pump.

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Pressure b ag moulding

This p rocess is re la ted to v a cuum ba g moulding in ex a ctly the sa me way as it sounds.A solid femal e mould is used al ong with a flexib le mal e mould.Reinforcement is p la ced inside the fem al e mould with just enough resin toall ow the f a b ric to stick in pla ce.Meas ured a mount of resin is then libe rally b rushed indi scrimina te ly into themould a nd the mou ld is then cla mped to a ma chine tha t conta ins the mal eflexib le mould.The flexib le mal e memb ra ne is then infla ted with he a ted comp ressed a ir or po ssibly stea m. The femal e mould ca n als o be he a ted.Excess resin is forced out al ong with tra pped a ir. This p rocess is exten sively used in the p roduction of compo site helmets due to the lowe r cost ofunskilled la bo r.Cycle times for a helmet b a g moulding ma chine vary from 20 to 45minutes, but the finished shells require no fu rther curing if the moulds ar ehea ted.

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Autoclave moulding

A process using a two-sided mou ld set tha t forms both surfa ces ofthe p a nel. On the lowe r side i s a rigid mold a nd on the uppe r side i s a flexib le memb ra ne ma de f rom silicone or a n ext ruded po lymer film such as nylon.Reinforcement ma te rials ca n be p la ced ma nually or robotically . They include continuous fibe r forms fas hioned into texti le constructions.Most often, the y ar e p re-impregn a ted with the resin in the form ofprep reg f a brics or unidirectional ta pe s.In some insta nces, a resin film is p la ced upon the lower mold a nd d ry reinforcement is p la ced a bove. The uppe r mold is install ed a nd

va cuum is a pp lied to the mo ld ca vity. The ass emb ly is p la ced into a na utocla ve. This process is gene rally pe rformed a t both e leva tedpressure a nd e leva ted tempe ra ture.The use of e leva ted p ressure f a cilita tes a high fibe r volume fra ctiona nd low void content fo r ma ximum structural efficiency.

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Resin transfer moulding (RTM)

A process using a two-sided mou ld set tha t fo rms both surfa ces of thepa nel. The lowe r side is a rigid mould. The uppe r side ca n be a rigid o r flexib le mould.Flexi b le moulds ca n be m a de f rom composite ma te rials , silicone orextruded polymer films such as nylon. The two side s fit togethe r to p roducea mould ca vity.The di stinguishing fea ture of resin tra nsfe r moulding is tha t thereinforcement ma terials ar e p la ced into this ca vity a nd the mou ld set is closed p rior to the int roduction of ma trix ma te rial .Resin tra nsfe r moulding include s numerous var ieties which differ in themecha nics of how the resin is introduced to the reinforcement in the mould

ca vity.These var ia tions include eve ry thing from va cuum infusion (for resin infusionsee als o boa t building) to va cuumass isted resin tra nsfe r moulding (VART M).This p rocess ca n be pe rformed a t eithe r a mbient or e leva ted tempe ra ture

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Othe r methods . . .

Molding & cas tingP ress moldingTra nsfe r moldingP ultrusion moldingFila ment windingCas ting- centrifugal cas ting a nd continuous cas ting.

Forming ca pa bilities CNC fila ment windingva cuum infusionwet lay -upcompression moldingthermoplas tic molding.

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P rope rties

O rthotropicdiffe rent depending on the di rection of the a pp lied fo rce o r loa d).The stiffness of a composite p a nel will often depend uponthe o rienta tion of the a pp lied fo rces a nd/o r moments. Pa nel stiffness is als o dependent on the de sign of the p a nel. For insta nce, the fibe r reinforcement a nd ma trix used, themethod of p a nel build, the rmoset ve rsus thermoplas tic, typeof we a ve, a nd o rienta tion of fibe r a xis to the p rimary force.

Isotropic ma te rials (Aluminium or S tee l), in sta ndar dwrought fo rms, typically ha ve thesa me stiffness reg ar d less of the di rectional orienta tion ofthe a pp lied fo rces a nd/o r moments.

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P rope rties impa ct . . .Re la tionship between fo rces/moment s a nd stra ins/cu rva tures for a n isotropic ma te rial

Described with the fo llowing ma te rial p rope rties: Young's Modulus, the S hear Modulus a nd the Poisson's ra tio, in re la tively simple ma thema tical re la tionships.

Anisotropic ma te rialRequires the ma thema tics of a second o rde r tensor a nd up to 21 m a terial prope rty consta nts.

O r thogonal isotropythere ar e three diffe rent ma terial prope r ty consta nts for ea ch of Young's Modulus, S hear Modulus a nd Poisson's ra tio a total of 9 con sta nts to de scribethe re la tionship between fo rces/moment s a nd stra ins/cu rva tures.

Techniques tha t ta ke a dva nta ge of the a nistropic p rope r ties of thema te rials include mor tise a nd tenon joints (in na tural composites such as wood) a nd P i Joints in synthetic composites.

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Resins . . .

Most common composite ma te rialsfibe rg lass , car bon fibe r, a nd Kevlar , include a t leas t two p ar ts,the substra te a nd the resin.

Polyeste r resinTend s to ha ve ye llowish tintW ea knesses - UV sensitive a nd ca n tend to deg ra de ove r time,a nd thus gene rally is als o coa ted to he lp p reserve it.

It is often u sed in the m a king of surfbo ar ds a nd fo r mar inea pp lica tions.

Its har dene r is a MEKP

- methyl ethyl ketone pe roxide, a ca talys t- is mixed a t 14 d rop s pe r oz. MEKP is composed of.W hen MEKP is mixed with the resin, the resulting chemical rea ction ca uses hea t to bui ld up a nd cure o r har den the resin.

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Resins . . .

Vinylester resinTend s to ha ve a purp lish to b luish to g reenish tint.Lower viscosity tha n po lyeste r resinMore t ra nspar entOften bi lled as being fue l resista ntBut will melt in conta ct with gas olineTend s to be mo re resista nt ove r time to deg ra da tion tha npo lyeste r resin, a nd is more f lexib le.

Epoxy resinAlmost totally tra nspar ent when cured.Aerospa ce industry - epox y is used as a structural ma trixma te rial or as a structural g lue.

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Resins . . .

Shape memory polymer (SMP) resinsVary ing visual chara cteristics depending on thei r formula tionmay be epox y - bas ed - u sed fo r a uto bod y a nd outdoo r equipment rep a irscya na te-e ster-bas ed - u sed in spa ce a pp lica tions

a cryla te-b as ed - u sed in ve ry cold tempe ra ture a pp lica tions, such as for sensors tha t indica te whethe r pe risha b le good s ha ve war med a bove a cer ta in ma ximumtempe ra tureunique - their sha pe c a n be repe a ted ly cha nged b y hea ting a bove thei r g lass tra nsition tempe ra ture.

W hen hea ted, the y become f lexib le a nd e las tic, all owing fo r easy configura tionOnce the y ar e coo led, the y will ma inta in their new sha pe. The resins will return totheir original sha pe s when they ar e rehe a ted a bove thei r Tg .The a dva nta ge of sha pe memo ry po lymer resins

Ca n be sha ped a nd resha ped repe a ted ly without losing their ma te rial prope rties, a ndthese resins ca n be u sed in f a brica ting sha pe memo ry composites.

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Fa ilure . . .

DelaminationS hock, impa ct, or repe a ted c yclic stresses ca n ca use the la mina teto sep ara te a t the inte rfa ce between two lay ers

Fib er Pull OutIndividual fibe rs ca n sep ara te f rom the ma trixComposites ca n fa il on the microscopic or ma croscopic scal e.

Compression failures ca n occur a t both the m a cro scal e o r a tea ch individual reinforcing fibe r in compression buckling.Tension failures ca n be net section fa ilures of the p ar t or deg ra da tion of the compo site a t a microscopic scal e whe re oneor more of the lay ers in the composite fa il in tension of the ma trixor fa ilure the bond between the m a trix a nd fibe rs.

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Fa ilure . . .

Brittle and have little reserve strength be yond theinitial onset of f a ilure while othe rs may ha ve lar gedefo rma tions a nd ha ve rese rve ene rgy a bsorbingca pa city pas t the on set of d a ma ge.The variations in fi b ers and matrices that areavaila b le and the mixtures tha t ca n be m a de with

blend

s le

ave

ave

ryb

ro

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range of p

rope

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atca n be de signed into a composite structure.

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Best known fa ilure . . .

Space Shuttle Colum b iaThe be st known fa ilure of a brittle ce ra mic ma trixcomposite occurr ed when the c ar bon-car boncomposite tile on the lea ding edge of the wing ofthe S pa ce S huttle Co lumbia fra ctured whenimpa cted du ring ta ke-off. It led to c a tas trophicbrea k-up of the vehic le when it re-ente red the

Ear th's a tmosphe re on Feb ruary 1, 2003.Compar ed to met als , composites ha ve re la tively poo r be ar ing strength.

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Testing . . .

To a id in p redicting a nd p reventing f a ilures Composites ar e te sted b efore and after construction.

P re-construction testingfinite e lement a nalys is (FEA) for p ly-by-p ly a nalys is ofcurved surfa ces a nd p redicting w rinkling, crimping a nddimpling of compo sites.

After constructionNonde structive methods

Ultras

onics

Thermogra phyS hear og ra phyX-ray ra diog ra phy

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Ma te rials . . .

Fibe r-reinforced po lymers -W ood (comp rising ce llulose fibe rs in a lignin a nd hemicellulosema trix),car bon-fibe r reinforced p las tic , CFRP

G lass -reinforced p las tic ,GRPClass ified b y ma trixthermoplas tic composites

S hort fibe r thermoplas ticsLong fiber thermoplas tics or long fibe r-reinforced the rmoplas tics.

Thermoset composites - but a dva nced sys tems usually incorpo ra te ara mid fibre a nd car bon fib re in a n epox y resinma trix.

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S ha pe Memo ry po lymer composites . . .

H igh-pe rforma nce composites formula ted u sing fibe r or fa b ric reinforcement a nd sha pe memo ry po lymer resin as the ma trix.

S ince a sha pe memo ry po lymer resin is used as the ma trix,

ha ve the a bility to be e as ily ma nipula ted into v ar ious configura tions when they ar e he a ted a bove thei r a ctiva tion tempe ra tures a nd will exhibit high strength a nd stiffness a t lowe r tempe ra tures.Ca n als o be rehe a ted a nd resha ped repe a ted ly without losing their ma te rial p rope rties.

Ideal for a pp lica tions such as

Lightweight / rigiddep loya b le structuresra pid ma nufa cturingdyna mic reinforcement

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Metal ma trix a nd Ce ra mic Ma trix. . .

Composites - use met al fibres reinforcing othe r metals , as in metal ma trix composites or MMC.

The benefit of m a gne sium is tha t it doe s not deg ra de in oute r spa ce.Cera mic ma trix composites

bone (hyd roxya pa tite reinforced with colla gen fibe rs)Cermet (cera mica nd metal ) a nd concrete .For toughne ss not for strength.

O rga nic ma trix/ce ra mic a gg reg a te compo sites Asphal t concrete,mas tic as phal t,mas tic roller hybrid,dent al composite,synta ctic foa m a nd mother of pe arl .Chobha m ar mour is a special type of composite ar mour used in military a pp lica tions.

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Thermoplas tic composite . . .

Formula ted with specific metal powde rs resulting in ma te rials with a den sity ra nge f rom 2 g/cm to 11 g/cm ( sa me den sity as lea d).Common na me - H igh G ra vity Compound (HG C),

Ca n be u sed in p la ce of t ra ditional ma te rials such as al uminum,sta inless stee l, brass , b ronze, coppe r, lea d, a nd even tung sten in weighting,bala ncing (for exa mple, modify ing the cente r of g ra vity of a tennis ra cquet)

H igh den sity composites a n economically via b le option when ce rta in ma terials ar e deemedha zar dous a nd ar e b a nned (such as lea d) or when second ary ope ra tions costs (such as ma chining, finishing, or coa ting) ar e a fa ctor.

App lica tions . . .Vibra tion da mpeningRa dia tion shielding

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Engineered W ood . . .

W ood al te rna tes . . .P lywoodOriented stra nd bo ar dW ood p las tic composite (recycled wood fibe r in polyethylenema trix)P ykrete (sa wdust in ice ma trix)

P las tic-impregn a ted o r la mina ted p a pe r or texti lesArbo rite, Formica (plas tic) a nd Micar ta .

La mina te compo sites,Mall ite, use a central core of end g ra in balsa wood, bonded tosurfa ce skins of light all oy or GRP .G ene ra te low-weight, high rigidity ma te rials .

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Online Da ta bas e . . .

Online, sear cha b le d a ta bas e of compo site ma te rial da ta sheet s.

Delivers a single loca tion to obt a in ma te rial da ta quickly loca te, compar e a nd eval ua te ca ndida te compo sites.Ma nufa cture rs supp lied d a ta

the d a ta bas e is popu la ted with qu al ity da ta from some of theworld s foremost te sting la bs a nd resear ch institutions

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Composite Design a nd Analys is . . .

Tools to he lp you meet compo site de sign & a nalys is chall enge s.W hen char ts a nd ta b les just ar ent enough, a ndfinite e lement a nalys is is too much,CompositeP ro fi lls the void with function a ndval ue.The new gene ra tion provide s the p rovenfunctional ity of the o riginal al ong with enha nceda nalys is a nd use r interfa ce ca pa bilities.

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App lica tion ar eas . . .

Mar ine tra nspo r tBuildings a nd civil infras tructureS po r ting good sMedical equipmentP rosthetic device s

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Areas . . .

Efficient ma nufa cturing techniquesEconomical a nd effective rep a ir techniquesMethods to p redict the shor t a nd long-te rmbeh a vior of the compo site ma te rials a nd structures ma de of the se ma te rials unde r a var iety of loa dingImpa ct on environment.Experimental testing equipmentLa test in computa tional a nalys is tools

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New compo sites . . .

G ra phene b as ed compo sitesThe method u ses g ra phite to p roduce individual g ra phene-bas ed sheet s

with exception al phys ical , chemical a nd b arr ier p rope rties tha t could bemixed into ma te rials such as po lymers, g lass es a nd ce ra mics.

App roxima te ly one million metric tons of g ra phite sold a nnually ar ound theworldRoughly 800 mi llion metric tons of unta pped n a tural g ra phite tha t could be

mined a nd used in the futu re, a ccording to the U. S . G eo logical S urvey.G ra phite is used in a wide var iety of a pp lica tions such as those re la ted tofriction (brake linings are one example), in gaskets, as a lubricant, and as anelectrode material in the making of steel.

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G ra phene b as ed compo sites

This resear ch provide s a bas is for deve loping a new class ofcomposite ma terials for ma ny a pp lica tions, through tuning oftheir

e lectrical a nd the rmal conductivity,mecha nical stiffnesstoughness a nd strengthpe rmea bility to f low var ious gas es through them

Ruoff, p rofe ssor of mecha nical enginee ring in the McCormickS chool of Engineering a nd App lied S cience."W e believe that manipulating the chemical and physical properties of

individual graphene-based sheets and effectively mixing them into other

materials will lead to discoveries of new materials in the future .

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Resear ch ongoing . . .

Experimental and numerical study of the slamming wave impact on deforma b lecomposite structures

Funda mental resear ch project 2009-2012 ( region al funding by FW O-Vlaa nde ren) (in collaboration with the Department of Heat, Combustion and Fluid Mechanics (Ghent University) and the Acoustics and Vibration Research Group (FreeUniversity of Brussels))

Sensing and morphing of composite laminates with piezoelectric transducersFunda mental resear ch project 2007-2009 (funding b y China S cholars hipCouncil)Monitoring deformation and degradation in thermoplastic composite materialswith draw tower Bragg grating optical fi b re sensors

App lied resear ch project 2007-2010 (indu strial funding)Speckle metrology techniques for contactless full-field measurement of in-planeand out-of-plane deformations of composite plates under static and dynamicloading conditions

Colla bo ra tive resear ch project 2006-2008 ( region al funding by FW O-Vlaa nde ren) (in collaboration with the Bulgarian Academy of Sciences)

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Resear ch ongoing . . .Development of a "stacked" solid-like shell element for the simulation of damage in largecomposite structures under dynamic loading conditions

Funda mental resear ch p roject 2007-2010 ( regional funding by FW O-Vlaa nde ren)(in collaboration with the research group Mechanics of Materials, Fluids and Structures(MS2F) (Universite de Liege))

The energy a b sorption assessment of composite structures for protection of civilengineering structures against b last loading

Funda mental resear ch p roject 2007-2010 ( regional funding by FW O-Vlaa nde ren)(in collaboration with the research group Mechanics of Materials and Constructions(MeMC) (Free University of Brussels) and the Royal Military Academy)

Experimental and numerical study of impact on window glass (retro)fitted with safety filmApp lied resear ch p roject 2006-2010 (indu strial funding)

High speed digital camera with high framerate and resolution for digital registration ofhighly dynamic phenomena

Resear ch infras tructure 2006 (funding b y G hent University)Experimental testing and numerical simulation of wear and damage in filament woundcomposite bearings

Funda mental resear ch p roject 2007-2010 (funding b y G hent University)(in collaboration with the research group Tribology and Fatigue (Ghent University))

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Resear ch Ongoing . . .

[Micro-meso-macro homogenization of the fatigue degradation of textilereinforced compositesFunda mental resear ch project 2006-2009 ( region al funding by FW O-Vlaa nde ren)(in collaboration with the department of Metallurgy and Materials Engineering(KULeuven))Experimental and theoretical study of the damage behaviour of fi b re-reinforced

composite systems under b iaxial fatigue loadingFunda mental resear ch project 2006-2009 ( region al funding by FW O-Vlaa nde ren)(in collaboration with the research group Mechanics of Materials and Constructions(MeMC) (Free University of Brussels)Modelling the fatigue behaviour of impact-damaged composites

Funda mental resear ch project 2006-2008 ( region al funding by FW O-Vlaa nde ren)Sustaina b le Economically Efficient Wave Energy Converter (SEEWEC)

App lied resear ch project 2006-2008 (Eu rope a n funding b y FP 6)

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Resear ch Ongoing . . .

Multi-Axial Stress and Strain sensing of thermo hardened composite elementsusing Fib re Optic Sensors (MASS FOS)App lied resear ch project 2006-2008 (funding b y Europe a n S pa ce Agency (ES A))OPTIcal MEasurement techniques for Structures and Systems (OPTIMESS)

S cientific resear ch network 2009-2013 ( region al funding by FW O-Vlaa nde ren)Mechanical and tri b ochemical energy dissipation process in structural

composites applied for complex rolling-sliding contact conditions: on-lineanalysis by means of computer vision and material response on meso-scaleFunda mental resear ch project 2008-2011 ( region al funding by FW O-Vlaa nde ren)(in collaboration with the research group Tribology and Fatigue (Ghent University), theresearch group Image Processing and Interpretation (Ghent University) and thedepartment of Metallurgy and Materials Engineering (KULeuven))Effects of flax fi b re reinforcement on the mechanical properties and riding

confort of a composite racing b icycle frameApp lied resear ch project 2009-2011 (indu strial funding)

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Journals . . .

Journal of Composite MaterialsCountry : United S ta tesSubj ect Area : Ma te rials S cienceSubj ect Category : Cera mics a nd Compo sites Pub lisher : S AG E P ublica tions. Pub lication type : Journals . ISSN: 00219983, 1530793 X

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Journals . . .

Editor Charl es E. Ba kis, P h.D.,The Pennsylva nia S ta te

UniversityFrequenc y BimonthlyISS N: 1090-0268

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Journals . . .

Applied Composite MaterialsS pringer Nethe rla ndsP rint a nd On line

Chemistry a nd Ma te rials S cience

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Journals . . .

Advanced CompositeMaterials

The official Journal of the

Ja pa n S ociety for Composite Ma te rials a ndthe Korea S ociety for Composite Ma te rials

Editors-in-Chief: H

.Fukuna ga (S end a i, Ja pa n )a nd K.S . H a n (S eou l, Korea )

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Composite Materials - Research Options