course code:ebb 337 course code:ebb 337 course title:advanced materials and composites course...
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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
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: 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
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
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