textile composites and its application

COMPOSITES

BY ALANKAR G. MHATRE
FINAL YEAR B.TECH

CONTENTS
• Introduction
• What are composites?
• Composition of composites
• Types of composites
• Manufacturing and forming methods
• Applications
• Composites Today's Material of Choice
• Properties of composites
• Key manufacturers of composite products
• References

INTRODUCTION TO COMPOSITES

 You might be know we all are surrounded by composites in day today life.
 Everybody comes across composites in his daily life.You might be playing
tennis or badminton with a "graphite racket", You might have a "carbon bike"
,your bike breaks are made of composite, several parts of your car body
are also made of composites.

 Def :-A composite is a material made up of two or more different materials
that are combined in a way that allows the materials to stay distinct and
identifiable.

 The purpose of composites is to allow the new material to have strengths
from both materials.

• Composites can be easily found in nature. Wood is an example of a
composite . Another natural composite is rock and sand, materials used in
concrete.

 Properties of composites like stiffness, thermal expansion etc. can be
varied continuously over a broad range of values using appropriate
fiber , resin and fabrication mechanism.

 The technical textile material in the composites is the fiber glass,
aramid and carbon fiber.
• Fibre glass dominates the composites industry as a preferred
reinforcement fibre, with a share of around 85%-90%. Other
reinforcement fibers like carbon fibre and aramid fibre are sparingly
used in India.

WHAT ARE COMPOSITES?
 Composites are created by combining two or more materials to
produce a new material that retains important properties from the
original elements .
 Reinforcing fibers give composites the attributes of high strength
and stiffness.
 In textile composites fibers are surrounded by a choice of polymers
that act as a support system.
 Composites are produced by reinforcing a resin matrix
(thermoplastic/thermoset) with fibres like glass fibre, aramid, carbon
fibre and/or natural fibres.

 A common example of a composite is concrete. It
consists of a binder as a cement and a reinforcement as
a gravel.

COMPOSITION OF COMPOSITES
 The individual materials that make up composites are called
constituents. Most composites have two constituents, a matrix and
reinforcement.

 Composite materials are usually classified by the type of
reinforcement they use. This reinforcement is embedded into a matrix
that hold it together.

 The reinforcement is used to strengthen the composite. Composite
properties are best in the direction of the fibers. Perpendicular, or
transverse, to the fibers, the matrix properties dominate because load
must be transferred by the matrix every fiber diameter.

Reinforcement
 The reinforcement is usually much stronger and stiffer than the matrix, and
that gives the composite its good properties.
 The matrix hold the reinforcements in an orderly pattern, the matrix also
helps to transfer load among the reinforcements.

 Reinforcements basically come in three forms: particulate, discontinuous
fiber, and continuous fiber.

PARTICLE AS A REINFORCEMENT:-A particle has roughly equal
dimensions in all directions, though it doesn't have to be spherical. Gravel,
micro balloons, and resin powder are examples of particulate
reinforcements.
CONTINUES FIBER AS A REINFORCEMENT:-Reinforcements
become fibers when one dimension becomes long compared to others.

DISCONTINUES FIBERS AS A REINFORCEMENT:
-:Discontinuous reinforcements (chopped fibers, milled fibers, or whiskers)
vary in length from a few millimeters to a few centimeters. Most fibers are
only a few microns in diameter, so it doesn't take much length to make the
transition from particle to fiber.

MATRIX
 Matrix materials are usually some type of plastic, and
these composites are often called reinforced plastics.

 There are other types of matrices, such as metal or
ceramic, but plastics are the most .
 The two most common plastic matrices are epoxy
resins and polyester resins.

TYPES OF COMPOSITES

 Metal matrix composites (MMC)

 Ceramic matrix composites (CMC)

 Polymer matrix composites (PMC)

Metal matrix composites (MMC)
• Metal matrix composites (MMCs) are a subgroup of composite materials.
 Composition:-
 MMC are made by dispersing a reinforcing material into a metal matrix. The
reinforcement surface can be coated to prevent a chemical reaction with the
matrix.
 -- For example, carbon fibers are commonly used in aluminum matrix
to synthesize composites showing low density and high strength. However,
carbon reacts with aluminum to generate a brittle and water-soluble
compound Al4C3 on the surface of the fiber. To prevent this reaction, the
carbon fibers are coated with nickel or titanium boride.
 Matrix:-
 In structural applications, the matrix is usually a lighter metal such as
aluminum, magnesium, or titanium, and provides a compliant support for the
reinforcement.
 In high temperature applications, cobalt and cobalt-nickel alloy matrices are
common.

Reinforcement to MMC
 The reinforcement can be either continuous, or discontinuous..
Discontinuous MMC can be isotropic, and can be worked with
standard metalworking techniques, such as extrusion, forging or
rolling.

 In addition, they may be machined using conventional techniques,
but commonly would need the use of polycrystalline diamond tooling
(PCD).

 Continuous reinforcement uses monofilament wires or
fibers such as carbon fiber or silicon carbide.

 One of the first MMC used boron filament as
reinforcement. Discontinuous reinforcement uses
"whiskers", short fibers, or particles.

 The most common reinforcing materials in this category
are alumina and silicon carbide.

Ceramic matrix composites
 Ceramic matrix composites (CMCs) are a subgroup of composite
materials as well as a subgroup of technical ceramics.

 They consist of ceramic fibers embedded in a ceramic matrix, thus
forming a ceramic fiber reinforced ceramic (CFRC) material.

 The matrix and fibers can consist of any ceramic material, whereby
carbon and carbon fibers can also be considered a ceramic
material.
 Generally, CMC names include a combination of type of fiber / type
of matrix. For example, C/C stands for carbon-fiber-reinforced
carbon (carbon/carbon), or C/ SiC for carbon-fiber-reinforced
silicon carbide.

Ceramic composites

REINFORCEMENT- SiC (Silicon carbide)
MATRIX-Cu Metal

Polymer Matrix composites
 Polymer matrix composites are the imp and third subgroup of
composites.
 It is also referred as fibre-reinforced plastics(FRP)
 In these fibre-reinforced plastics, the plastic is reinforced with
fibers to make a light and strong material. The material in which
the fibres are embedded, is called the matrix, while the fibres are
called the reinforcement.
 The matrix can basically be any type of plastic: epoxy, polyester,
vinyl ester, polypropylene (PP).

Matrix examples for PMC
• Thermosetting resins • Thermoplastic resins
• Epoxy • polypropylene (PP)
• unsaturated polyester • thermoplastic polyesters
(UP) (PET, PBT)
• Vinylester • polyether sulphide (PES)
• polyurethane (PUR) • polyphenylene sulphide
• phenolic resin (PPS)
• acrylic resin • polyether imide (PEI)
• polyether ether ketone
(PEEK)

Glass fabrics Plain weave glass
fabric

The fibres are typically glass, carbon (graphite) or aramid (trade
name Kevlar). The fibre reinforcement can take any form: a mat
of short chopped fibres, a woven fabric, a unidirectional
arrangement of fibres, a braid, a knit.

Manufacturing and forming methods of
MMC
 MMC manufacturing can be broken into three types: solid,
liquid, and vapor.
Solid state methods:-
 1)-Powder blending and consolidation (powder metallurgy):-
Powdered metal and discontinuous reinforcement are mixed
and then bonded through a process of compaction, degassing,
and thermo-mechanical treatment (possibly via hot isostatic
pressing (HIP) or extrusion).
 2)-Foil diffusion bonding:-Layers of metal foil are
sandwiched with long fibers, and then pressed through to form
a matrix.

Liquid state methods FOR MMC

 1)-Electroplating / Electroforming:- A solution
containing metal ions loaded with reinforcing particles is
co-deposited forming a composite material.
 2)-Stir casting:- Discontinuous reinforcement is stirred
into molten metal, which is allowed to solidify.
 3)-Squeeze casting:- Molten metal is injected into a
form with fibers preplaced inside it.
 4)-Spray deposition:- Molten metal is sprayed onto a
continuous fiber substrate.
 5)-Reactive processing:- A chemical reaction occurs,
with one of the reactants forming the matrix and the
other the reinforcement.

Vapor deposition
 Physical vapor deposition: The fiber is
passed through a thick cloud of vaporized
metal, coating it.

Manufacturing procedures for Ceramic
matrix composites
1)-Matrix deposition from a gas phase:-

 Chemical vapor deposition (CVD) is well suited for this purpose.
In the presence of a fiber perform, CVD takes place in between the fibers
and their individual filaments and therefore is called chemical vapor
infiltration (CVI).

 One example is the manufacture of C/C composites: a C-fiber perform is
exposed to a mixture of argon and a hydrocarbon gas (methane, propane,
etc.) at a pressure of around or below 100 kPa and a temperature above
1000 °C.

2)-Matrix forming via pyrolysis of C- and Si-containing polymers-

 Hydrocarbon polymers shrink during paralysis, and upon out gassing form
carbon with an amorphous, glass-like structure, which by additional heat
treatment can be changed to a more graphite-like structure.

 Other special polymers, where some carbon atoms are replaced by
silicon atoms, the so-called polycarbosilanes, yield amorphous silicon
carbide of more or less stoichiometric composition.

• Subsequent curing and pyrolysis yield a highly porous matrix, which is
undesirable for most applications. Further cycles of polymer infiltration and
pyrolysis are performed until the final and desired quality is achieved.
Usually five to eight cycles are necessary .

 The process is called liquid polymer infiltration (LPI), or polymer
infiltration and pyrolysis (PIP). Here also a porosity of about 15% is
common due to the shrinking of the polymer. The porosity is reduced after
every cycle.

APPLICATION OF COMPOSITES
• Applications of Métal matrix composites (MMC)–
• Carbide drills are often made from a tough cobalt matrix with hard tungsten
carbide particles inside.
• Some tank armors may be made from metal matrix composites, probably steel
reinforced with boron nitride. Boron nitride is a good reinforcement for steel
because it is very stiff and it does not dissolve in molten steel.
• Honda , Toyotas automobiles has used aluminum metal matrix composite
cylinder liners in some of their engines,
• Specialized Bicycles has used aluminum MMC compounds for its top of the
range bicycle frames for several years. Griffen Bicycles also makes boron
carbide-aluminum MMC bike frames, and Univega briefly did so as well.

• Some automotive disc brakes use MMC. Modern high-performance sport
cars, such as those built by Porsche, use rotors made of carbon fiber
within a silicon carbide matrix because of its high specific heat and
thermal conductivity.

A typical composites material construction
for helicopter blade

Applications Of ceramic matrix composites
• Heat shield systems for space vehicles, which are needed during the re-entry
phase, where high temperatures, thermal shock conditions and heavy vibration
loads take place.
• Components for high-temperature gas turbines such as combustion chambers,
and turbine blades.
• Components for burners, flame holders, and hot gas ducts, where the use of oxide
CMCs has found its way.
• Disks breaks and brake system components, which experience extreme thermal
shock .

Applications of FRP or PMC
• Fibre-reinforced plastics are best suited for any design program that
demands weight savings, precision engineering, finite tolerances, and the
simplification of parts in both production and operation. A moulded polymer
artefact is cheaper, faster, and easier to manufacture than cast aluminum or
steel artefact, and maintains similar and sometimes better tolerances and
material strengths.
• Overall reduction in production and operational costs, economy of parts
results in lower production costs and the weight savings create fuel savings
that lower the operational costs of flying the aero plane.

Design considerations

PMC IN AIRCRAFT PARTS
LIGHT WEIGHT

APPLICATION PMC IN RAILWAYS

 For passenger coach components.
 Components of coaches are generally made of glass
fibre reinforced with polyesters/epoxies, phenolic
resins.

Minardi Formula 1
All Formula One race cars have a carbon
fibre monocoque structure that protects
the driver for all crashes.

BMC frame with carbon/epoxy pre-preg

One of the most well-known composite applications in
sports is the so-called "carbon bike". The frame consists
of carbon fibre-reinforced epoxy which makes the
frame very stiff and lightweight.

BMW M6 with carbon fibre roof
In automotive applications, composites are all around us. Just as
in sports applications, weight reduction is pushing the designers to
use more and more composites. The examples are numerous.

Composites Today's Material of
Choice
 It gives lower manufacturing costs, composite material continues to
penetrate new markets and applications. For industries that
traditionally use assemblies made from more traditional options such
as steel, wood or concrete, composites offer a dynamic alternative –
especially for those products that are difficult to assemble or costly to
manufacture as a result of increasing steel pieces. Glass fibre as
reinforcement dominates the sector of composites material with a
share of 85-90%.
• Composites are created by combining two or more materials to produce a
new material that retains important properties from the original elements.
 Reinforcing fibers give composites the attributes of high strength and
stiffness which in the industrial arena translates to high performance.
These fibers are surrounded by a choice of polymers that act as a support
system, transferring load between fibers and protecting the fibers from the
operating environment.The burgeoning infrastructure sectors project
involving highways, bridges, airports, buildings, and construction,
power generation and transmission, telecommunications are expected
to provide an impetus to the composites industry in India.

 Composites can also deliver reduced manufacturing/assembly
costs. Since liquid resin can flow into any shape, products with
complex shapes can be made at a lower cost when compared
to conventional methods using traditional materials.
• Typically, complex shapes of metals or wood require labor intensive
assembly of multiple pieces to create the product. Composites can
provide ultimately the lowest cost alternative.
 The lower cost of unitized composite parts is particularly
attractive for customers that purchase products assembled
from many metallic pieces or have difficult-to-form shapes.

Properties of composite
products
 Tensile strength of composites is four to six times greater than that of
conventional materials like steel, aluminium etc.

 Improved torsion stiffness and impact properties .

 Higher fatigue endurance limit (up to 60% of the ultimate tensile strength)
 30-45% lighter than aluminium structures designed for the same functional
requirements .

 Lower embedded energy .

 Composites are less noisy while in operation and provide lower vibration
transmission

 Composites are more versatile and can be tailored to meet performance
needs and complex design requirements

 Long life offers excellent fatigue, impact, environmental
resistance and reduced maintenance.
Composites enjoy reduced maintenance cost

 Composites exhibit excellent corrosion resistance and fire
retardant capability

 Improved appearance with smooth surfaces and readily
incorporable integral decorative melamine are other
characteristics of composites

• Composite parts can eliminate joints/fasteners, providing part
simplification and integrated design.
 25% reduction in weight
 95% reduction in components by combining parts and forms
into simpler moulded parts.

Key manufacturers of composite
products:-
1. Saertex India – Saertex India is 100% subsidiary of
Saertex. Saertex, is a major player in the stitch-bonded
fabric segment.
The company has six manufacturing facilities
across the globe and the Indian facility at Pune is the
seventh. Saertex India has production capacity of
around 10,000 – 11,000 MT of composite fabric.
Additionally, Saertex has 12 MT production.capacity for
specialty fibres. Saertex is one of major suppliers of
composite material for windmill blade fabrication.
Saertex plans to enter automotive sector for
development of composite based vehicle bodies (three-
wheelers, buses and cars).

2.) DSM Engineering Plastics – DSM is one of the
major players in high-performance composites.
-DSM had a capacity of 7,000 MT in 2007 which was
expected to scale up to 20,000 MT.
3) Kemrock Industries – Kemrock Industries has
composite production capabilities like Pultrusion,
 Resin Transfer Moulding, Compression Moulding, Vaccum
Resin Transfer Moulding,
 Centrifugal Casting, Filament Winding etc. for fibre-glass
reinforced composites.
• comprehensive dough moulding composites based
manufacturing facility for specialty resins.

textile composites and its application

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