Polymer Composites

Poly E-410

Dr Atif Javaid

Polymer & Process Engineering Department

University of Engineering & Technology, Lahore

Email:
atifjavaid@uet.edu.pk

Lecture 1

Outline

Composites
Introduction
History
Pros and Cons of Composites
Considerations
Types of Composites
Types of fibres

Useful Web-sites & Books:

The macrogallaria a virtual introduction to polymers
http://www.psrc.usm.edu/macrog/index.htm
Composites an introduction
http://www.psrc.usm.edu/macrog/composit.htm
Tutorial on Polymer Composite Moulding!
http://islnotes.cps.msu.edu/trp/index.html
D. Hull & T.W. Clyne, An Introduction to Composite Materials,
2nd Ed., Cambridge University Press, 1997.
J.M.G. Cowie, Polymers: Chemistry & Physics of Modern
Materials,
2nd Ed., nelson thornes, 2001.
R. Bonnett, R.J. Young & P. Lovell, Introduction to Polymers,
2nd Ed., Chapman & Hall, 1991.
H.-G. Elias, An Introduction to Polymer Science, VCH, Weinheim,
1997.

Course Contents
Introduction to modern structural composites and
unique applications;
Material system;
Methods of computing average properties;
Composite fabrication techniques,
Rheology of composites and viscoelasticity;
Overview of mechanics of composite material;
Design of composites,
Composite testing,
Nano-composites,
Sandwich composites & Structural composites

Lecture Breakdown
Week 1
Introduction of polymer composites, History, Pros and Cons of Composites
Considerations, Types of Composites
Types of fibres: Glass fibres, Carbon fibres, Aramid fibres, Polyethylene fibres,
Ceramic fibres
Woven Architectures

Week 2
Polymer Matrices
Metal Matrix Composites (GLARE) and Ceramic Matrix Composites
Polymer Matrix Issues, Applications of Polymer Composites

Week 3
Processing of Polymer Composites: Prepregs, Short fibre composites, Filament,
tow and fibre placement, Filament Winding, Automatic Fibre Placement,
Pultrusion, Vacuum/Pressure bag, Autoclave Moulding

Lecture Breakdown
Week 4
Processing of polymer composites: Contact moulding, Resin film infusion, Resin
infusion under flexible tooling (RIFT), Compression Moulding, Resin transfer
moulding (RTM)
Processing of Thermoplastic Polymer Composites
Non-Crimp fabrics / Uniweave, Through thickness (t/t) reinforcements
3D Composites

Week 5
Multiply laminates
Processing of Polymer Composites Case study Example - Swedish Visby
Corvette

Week 6
Mechanical Properties of Polymers
Rheology of composites and viscoelasticity

Lecture Breakdown
Week 7
Mechanical Characterisation at Fiber/ Matrix Interphase: Single fibre pull-out test,
Single fibre push-out test, Compression of single fibre embedded in resin, Single
fibre fragmentation test

Week 8
Mechanical Properties of Polymer Composites, Rule of mixture, Volume fraction,
Stiffness Macro mechanics Model Stiffness, Parallel to fibres, Perpendicular to
fibres, Halpin Tsai Equations

Week 9
Mid Term Examination

Week 10
Failure in Polymer Composites

Week 11
Fracture mechanics of Polymer Composites
Fractography

Lecture Breakdown
Week 12
Polymer Nano-Composites, Carbon Nanotubes (CNTs): Types of CNTs, History of
CNTs, Properties of CNTs, Fabrication of CNTs, Applications of CNTs

Week 13
Recycling of Polymer Composites

Week 14
Material Selection in Polymer Composites

Week 15
Fibre surface treatments

Week 16
Latest Research Trends in Polymer Composites: Conductive Polymer
nanocomposites, Green Composites, Multifunctional Composites, Hierarchical
Polymer Composites, Thermoplastic Composites, Self healing Composites, Other
interesting research areas in Polymer Composites

Week 18

Final Examination

What Are Composites?

Composites are:

- a structural product of two (or more) identifiably distinct

materials

Definition

- engineering performance is exceeding those of any

individual component

Fibre Reinforced Polymers:

- Fibres carry load
- Fibre type, amount, orientation & alignment determine
effectiveness
- Matrix Polymer transfers load between fibres
- protects & holds fibres in place
- determines chemical resistance &
- mechanical properties at elevated temperatures

Introduction Definition of a Composite

Combine two or more discrete materials to make an improved material

Particulate

Short fibre

Continuous fibre

Laminated

Examples
(Concrete)

(Plastic boat hulls)

(Reinforced concrete)

(Plywood)

Introduction - History

Composites not new;

Straw reinforced bricks
Wattle huts & dams
Paper
Concrete

Recent interest in tailoring (designing)

materials for specific requirements;
Deliberate combination of two or more
constituents
Given rise to a range of industries
producing materials with a wide
spectrum of properties.

Wood

Natural composite (cellulose fibres in lignin) - excellent specific properties;

But susceptible to rotting & biological attack
Size limitations.

The latter problem is dealt with by making fabricated items such as plywood,
blockwood, laminated constructions (e.g. buildings, fan blades, etc).

Introduction Pros and Cons

ADVANTAGES
High stiffness & strength at low
weight
Properties can be tailored by choice
of matrix & reinforcement
Good corrosion resistance & fatigue
properties
Toughness through multiple crack
paths
DISADVANTAGES
Higher cost than most conventional
materials
Low strength & toughness in certain
directions
Most light (polymer) composites
unsuitable for high temperatures

Introduction - Considerations

Composites challenge conventional materials in many applications.

Problem;
Originally touted as the universal panacea for structural applications
Led to Inappropriate use of the material and poor design
Well publicised disasters (such as RB211)
Main difficulty is the black aluminium approach used in early designs.

Different Types of Composite

Basic approach is to incorporate a filler or reinforcement into a matrix.

Could be;
metal (MMC)
ceramic (CMC)
polymer (PMC)
hybrid (Fibre Metal Laminates; GLARE)
Particle, fibre or whisker - organic, inorganic or metallic material.
Often aim to improve mechanical property (toughness, strength, etc), or
sometimes just to reduce cost (e.g. aggregate in cement).

Different Types of Fibre Composite

Short fibre composites

Composite laminates
from unidirectional plies

2D weaves
(lower in-plane stiffness & strength)

3D weaves
(lower in-plane stiffness & strength)

Role of Reinforcement
Reinforcement:
carries most of the load
Matrix:
transfers load between reinforcement particles
support reinforcement against compressive buckling
provides toughening when individual reinforcement particle break
protects reinforcement from wear and environment
t

Ineffective
length

Summary/Recap

Composites
Introduction
History
Pros and Cons of Composites
Considerations
Types of Composites
Types of fibres