Title: Textile Structural Composites
1Textile Structural Composites
- Yiping Qiu
- College of Textiles
- Donghua University
- Spring, 2006
2Reading Assignment
- Textbook chapter 1 General Information.
- High-Performance Composites An Overview,
High-Performance Composites, 7-19, 2003
Sourcebook. - FRP Materials, Manufacturing Methods and Markets,
Composites Technology, Vol. 6(3) 6-20, 2000.
3Expectations
- At the conclusion of this section, you should be
able to - Describe the advantages and disadvantages of
fiber reinforced composite materials vs. other
materials - Describe the major applications of fiber
reinforced composites - Classification of composites
4Introduction
- What is a composite material?
- Two or more phases with different properties
- Why composite materials?
- Synergy
- History
- Current Status
5Introduction
- Applications
- Automotive
- Marine
- Civil engineering
- Space, aircraft and military
- Sports
6Applications in plane
7Fiber reinforced composite materials
- Classifications according to
- Matrices
- Polymer
- Thermoplastic
- Thermoset
- Metal
- Ceramic
- Others
8Fiber reinforced composite materials
- Classifications
- Fibers
- Length
- short fiber reinforced
- continuous fiber reinforced
- Composition
- Single fiber type
- Hybrid
- Mechanical properties
- Conventional
- Flexible
9Fiber reinforced composite materials
- Advantages
- High strength to weight ratio
- High stiffness to weight ratio
- High fatigue resistance
- No catastrophic failure
- Low thermal expansion in fiber oriented
directions - Resistance to chemicals and environmental factors
10Comparison of specific gravities
8
6
Specific gravity
(g/cc)
4
2
0
Steel
Al alloy
Ti alloy
Kevlar/epoxy
Carbon/epoxy
materials
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12(No Transcript)
13Fiber reinforced composite materials
- Disadvantages
- Good properties in one direction and poor
properties in other directions. - High cost due to expensive material and
complicated fabrication processes. - Some are brittle, such as carbon fiber reinforced
composites. - Not enough data for safety criteria.
14Design of Composite Materials
- Property Maps
- Merit index
15Design of Composite Materials
- Merit index
- Example for tensile stiffness of a beam
- However, for a given tensile sample, tensile
stiffness has nothing to do with length or L 1
may be assumed
16Design of Composite Materials
- How about for torsion beams and bending plates?
Lets make the derivation of these our first
homework.
17Major components for fiber-reinforced composites
- Reading assignment
- Textbook Chapter 2 Fibers and matrices
- Fibers
- Share major portion of the load
- Matrix
- To transfer stress between the fibers
- To provide a barrier against an adverse
environment - To protect the surface of the fibers from
mechanical abrasion
18Major components for fiber reinforced composites
- Coupling agents and coatings
- to improve the adhesion between the fiber and the
matrix - to protect fiber from being reacted with the
matrix or other environmental conditions such as
water moisture and reactive fluids. - Fillers and other additives
- to reduce the cost,
- to increase stiffness,
- to reduce shrinkage,
- to control viscosity,
- to produce smoother surface.
19Materials for fiber reinforced composites
- Mainly two components
- Fibers
- Matrices
20Materials for fiber reinforced composites
- Fibers
- Influences
- Specific gravity,
- Tensile and compressive strength and modulus,
- Fatigue properties,
- Electrical and thermal properties,
- Cost.
21Materials for fiber reinforced composites
- Fibers
- Fibers used in composites
- Polymeric fibers such as
- PE (Spectra 900, 1000)
- PPTA Poly(para-phenylene terephthalamide)
(Kevlar 29, 49, 149, 981, Twaron) - Polyester (Vectran or Vectra)
- PBZT Poly(p-phenylene benzobisthiozol)
22Materials for fiber reinforced composites
- Fibers
- Inorganic fibers
- Glass fibers S-glass and E-glass
- Carbon or graphite fibers from PAN and Pitch
- Ceramic fibers Boron, SiC, Al2O3
- Metal fibers steel, alloys of W, Ti, Ni, Mo etc.
(high melting temperature metal fibers)
23Materials for fiber reinforced composites
- Most frequently used fibers
- Glass
- Carbon/graphite
- PPTA (Kevlar, etc.)
- Polyethylene (Spectra)
- Polyester (Vectra)
24Materials for fiber reinforced composites
- Carbon fibers
- Manufacturing processes
- Structure and properties
25Materials for fiber reinforced composites
- Carbon fibers
- Manufacturing processes
- Thermal decomposition of fibrous organic
precursors - PAN and Rayon
- Extrusion of pitch fibers
26Materials for fiber reinforced composites
- Carbon fiber manufacturing processes
- Thermal decomposition of fibrous organic
precursors - Rayon fibers
- Rayon based carbon fibers
- Stabilization at 400C in O2, depolymerization
aromatization - Carbonization at 400-700C in an inert atmosphere
- Stretch and graphitization at 700-2800C (improve
orientation and increase crystallinity by 30-50)
27Materials for fiber reinforced composites
- Carbon fiber manufacturing processes
- Thermal decomposition of fibrous organic
precursors - PAN (polyarylonitrile) based carbon fibers
- PAN fibers (CH2-CH(CN))
- Stabilization at 200-300C in O2,
depolymerization aromatization, converting
thermoplastic PAN to a nonplastic cyclic or
ladder compound (CN groups combined and CH2
groups oxidized) - Carbonization at 1000-1500C in an inert
atmosphere to get rid of noncarbon elements (O
and N) but the molecular orientation is still
poor. - Stretch and graphitization at gt1800C, formation
of turbostratic structure
28Materials for fiber reinforced composites
- Pitch based carbon fibers
- pitch - high molecular weight byproduct of
distillation of petroleum - heated gt350C, condensation reaction, formation
of mesophase (LC) - melt spinning into pitch fibers
- conversion into graphite fibers at 2000C
29Materials for fiber reinforced composites
- Carbon fibers
- Advantages
- High strength
- Higher modulus
- Nonreactive
- Resistance to corrosion
- High heat resistance
- high tensile strength at elevated temperature
- Low density
30Materials for fiber reinforced composites
- Carbon fibers
- Disadvantages
- High cost
- Brittle
31Materials for fiber reinforced composites
- Carbon fibers
- Other interesting properties
- Lubricating properties
- Electrical conductivity
- Thermal conductivity
- Low to negative thermal expansion coefficient
32Materials for fiber reinforced composites
- Carbon fibers
- heat treatment below 1700C
- less crystalline
- and lower modulus (lt365 GPa)
- Graphite fibers
- heat treatment above 1700C
- More crystalline (80) and
- higher modulus (gt365GPa)
33Materials for fiber reinforced composites
- Glass fibers
- Compositions and properties
- Advantages and disadvantages
34Materials for fiber reinforced composites
- Glass fibers
- Compositions and Structures
- Mainly SiO2 oxides of Ca, B, Na, Fe, Al
- Highly cross-linked polymer
- Noncrystaline
- No orientation
- Si and O form tetrahedra with Si centered and O
at the corners forming a rigid network - Addition of Ca, Na, K with low valency breaks
up the network by forming ionic bonds with O ? ?
strength and modulus
35Microscopic view of glass fiber
Cross polar
First order red plate
36Materials for fiber reinforced composites
- Glass fibers
- Types and Properties
- E-glass (for electric)
- draws well
- good strength stiffness
- good electrical and weathering properties
37Materials for fiber reinforced composites
- Glass fibers
- Types and Properties
- C-glass (for corrosion)
- good resistance to corrosion
- low strength
38Materials for fiber reinforced composites
- Glass fibers
- Types and Properties
- S-glass (for strength)
- high strength modulus
- high temperature resistance
- more expensive than E
39Materials for fiber reinforced composites
- Properties of Glass fibers
40Materials for fiber reinforced composites
- Glass fibers
- Production
- Melt spinning
41Materials for fiber reinforced composites
- Glass fibers
- sizing
- purposes
- protest surface
- bond fibers together
- anti-static
- improve interfacial bonding
- Necessary constituents
- a film-forming polymer to provide protecting
- e.g. polyvinyl acetate
- a lubricant
- a coupling agent e.g. organosilane
42Materials for fiber reinforced composites
- Glass fibers
- Advantages
- high strength
- same strength and modulus in transverse direction
as in longitudinal direction - low cost
43Materials for fiber reinforced composites
- Glass fibers
- disadvantages
- relatively low modulus
- high specific density (2.62 g/cc)
- moisture sensitive
44Materials for fiber reinforced composites
- Kevlar fibers
- Structure
- Polyamide with benzene rings between amide groups
- Liquid crystalline
- Planar array and pleated system
45Materials for fiber reinforced composites
- Kevlar fibers
- Types
- Kevlar 29, E 50 GPa
- Kevlar 49, E 125 GPa
- Kevlar 149, E 185 GPa
46Materials for fiber reinforced composites
- Kevlar fibers
- Advantages
- high strength modulus
- low specific density (1.47g/cc)
- relatively high temperature resistance
47Materials for fiber reinforced composites
- Kevlar fibers
- Disadvantages
- Easy to fibrillate
- poor transverse properties
- susceptible to abrasion
48Materials for fiber reinforced composites
- Spectra fibers
- Structure (CH2CH2)n
- Linear polymer - easy to pack
- No reactive groups
- Advantages
- high strength and modulus
- low specific gravity
- excellent resistance to chemicals
- nontoxic for biomedical applications
49Materials for fiber reinforced composites
- Spectra fibers
- Disadvantages
- poor adhesion to matrix
- high creep
- low melting temperature
50Materials for fiber reinforced composites
- Other fibers
- SiC and Boron
- Production
- Chemical Vapor Deposition (CVD)
- Monofilament
- Carbon or Tungsten core heated by passing an
electrical current - Gaseous carbon containing silane
51Materials for fiber reinforced composites
- SiC
- Production
- Polycarbosilane (PCS)
- Multi-filaments
- polymerization process to produce precursor
- PCS pyrolised at 1300ºC
- Whiskers
- Small defect free single crystal
52Materials for fiber reinforced composites
- Particulate
- small aspect ratio
- high strength and modulus
- mostly cheap
53Materials for fiber reinforced composites
- The strength of reinforcements
- Compressive strength
- Fiber fracture and flexibility
- Statistical treatment of fiber strength
54Materials for fiber reinforced composites
- The strength of reinforcements
- Compressive strength
- (Mainly) Euler Buckling
55Materials for fiber reinforced composites
- The strength of reinforcements
- Factors determining compressive strength
- Matrix material
- Fiber diameter or aspect ratio (L/d)
- fiber properties
- carbon glass gtgt Kevlar
56Materials for fiber reinforced composites
- The strength of reinforcements
- Fiber fracture
- Mostly brittle
- e.g. Carbon, glass, SiC
- Some ductile
- e.g. Kevlar, Spectra
- Fibrillation
- e.g. Kevlar
57Materials for fiber reinforced composites
- The strength of reinforcements
- Fiber flexibility
- How easy to be bent
- Moment required to bend a round fiber
E Youngs Modulus d fiber diameter ?
curvature
58Materials for fiber reinforced composites
- The strength of reinforcements
- Fiber failure in bending
- Stress on surface
- Tensile stress
E Youngs Modulus d fiber diameter ?
curvature
59Materials for fiber reinforced composites
- The strength of reinforcements
- Fiber failure in bending
- Stress on surface
- Maximum curvature
? fiber tensile strength
60Materials for fiber reinforced composites
- The strength of reinforcements
- Fiber failure in bending
- When bent, many fibers fail in compression
- Kevlar forms kink bands
61Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Brittle materials failure caused by random flaw
- dont have a well defined tensile strength
- presence of a flaw population
- Statistical treatment of fiber strength
- Peirce (1928) divide a fiber into incremental
lengths
62Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Peirces experiment
- Hypothesis
- The longer the fiber length, the higher the
probability that it will contain a serious flaw. - Longer fibers have lower mean tensile strength.
- Longer fibers have smaller variation in tensile
strength.
63Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Peirces experiment
- Experimental verification
64Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Weakest Link Theory (WLT)
- define n? No. of flaws per unit length causing
failure under stress ?. - For the first element, the probability of failure
The probability for the fiber to survive
65Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Weakest Link Theory (WLT)
- If the length of each segment is very small, then
Pfi are all very small, - Therefore (1-Pfi) ? exp(-Pfi)
- The probability for the fiber to survive
66Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Weibull distribution of fiber strength
- Weibulls assumption
m Weibull shape parameter (modulus). ?0
Weibull scale parameter, characteristic
strength. L0 Arbitrary reference length.
67Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Weibull distribution of fiber strength
- Thus
68Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Weibull distribution of fiber strength
- Discussion
- Shape parameter ranges 2-20 for ceramic and many
other fibers. - The higher the shape parameter, the smaller the
variation. - When ? lt?0, the probability of failure is small
if m is large. - When ? ??0, failure occurs.
- Weibull distribution is used in bundle theory to
predict fiber bundle and composite strength.
69Materials for fiber reinforced composites
- Statistical treatment of fiber strength
- Weibull distribution of fiber strength
- Plot of fiber strength or failure strain data
- let
70Statistical treatment of fiber strength
- Example
- Estimate number of fibers fail at a gage length
twice as much as the gage length in single fiber
test - L/L0 2
71Matrices
- Additional reading assignment
- Jones, F.R., Handbook of Polymer-Fiber
Composites, sections - 2.4-2.6, 2.9, 2.10, 2.12.
72Matrices
73Matrices
- Polymer
- Thermosetting resins
- Epoxy
- Unsatulated polyester
- Vinyl ester
- high temperature
- Polyimides
- Phenolic resins
74Matrices
Polymer Target net resin properties
75Epoxy resins
- Starting materials
- Low molecular weight organic compounds containing
epoxide groups
76Epoxy Resins
77Epoxy resins
- Types of epoxy resin
- bifuctional diglycidyl ether of bisphenol A
- a distribution of monomers ? n is fractional
- effect of n
- ? molecular weight ? ? viscosity ? ? curing temp.
- ? distance between crosslinks ? ? Tg ?
ductility - ? -OH ? ?moisture absorption
78Epoxy resins
- Types of epoxy resin (cont.)
- Trifunctional (glycidyl amines)
- Tetrafunctional
- higher functionality
- potentially higher crosslink densities
- higher Tg
- Less -OH groups ? ? moisture absorption
79Epoxy resins
- Curing
- Copolymerization
- A hardener required e.g. DDS, DICY
- Hardeners have two active H atoms to add to the
epoxy groups of neighboring epoxy molecules,
usually from -NH2 - Formation of -OH groups moisture sensitive
- Addition polymerization No small molecules
formed ? no volatile formation - Stoichiometric concentration used, phr part per
hundred (parts) of resin
80Epoxy resin
- Major ingredients epoxy resin and curing agent
81Epoxy resin
82Epoxy resin
83Epoxy resins
- Curing
- Homopolymerization
- Addition polymerization a catalyst or initiator
required eg. Tertiary amines and BF3 compounds - Less -OH groups formed
- Typical properties of addition polymers
- Combination of catalyst with hardeners
84Epoxy Resins
- Reaction of homopolymerization
85Epoxy resins
- Epoxy resins
- Mechanical and thermomechanical properties
- Effect of curing agent on mechanical properties
- Heat distortion temperature (HDT)
- measured as temperature at which deflection of
0.25 mm of 100 mm long bar under 0.455 MPa fiber
stress occurs. - related but ? Tg
- Moisture absorption 1 decrease Tg by 20ºK
86Polyimides
- Largest class of high temperature polymers in
composites - Types
- PMR (polymerization of monomeric reactants)
- polyimides are insoluble and infusible.
- in situ condensation polymerization of monomers
in a solvent - 2 stage process
- first stage to form imidized prepolymer of
oligomer and volatile by-products removed using
autoclave or vacuum oven. - Second stage prepolymer is crosslinked via
reaction of the norbornene end cap under high
pressure and temperature (316ºC and 200 psi)
87Polyimides
- Types
- bis-imides (derived from monomers with 2
preformed imide groups). - Typical BMI (bismaleimides)
- Used for lower temperature range 200ºC
88Polyimides
89Polyimides
- Advantages
- Heat resistant
- Drawbacks
- toxicity of constituent chemicals (e.g. MDA)
- microcracking of fibers on thermal cycling
- high processing temperature
- Typical Applications
- Engine parts in aerospace industry
90Phenolic resins
- Prepared through condensation polymerization
between phenol and formaldehyde. - Large quantity of Water generated (up to 25)
leading to high void content
91Phenolic resins
- Advantages
- High temperature stability
- Chemical resistance
- Flame retardant
- Good electrical properties
- Typical applications
- Offshore structures
- Civil engineering
- Marine
- Auto parts water pumps, brake components
- pan handles and electric meter cases
92Time-temperature-transformation diagrams for
thermosets resins
- Additional reading assignment
- reserved Gillham, J.K., Formation and Properties
of Thermosetting and High Tg Polymeric Materials,
Polymer Engineering and Science, 26, 1986,
p1429-1431
93Time-temperature-transformation diagrams for
thermosets resins
94Time-temperature-transformation diagrams for
thermosets resins
- Important concepts
- Gelation
- formation of an infinite network
- sol and gel coexist
- Vitrification
- Tg rises to isothermal temperature of cure
- Tcure gt Tg, rubbery material
- Tcure lt Tg, glassy material
- After vitrification, conversion of monomer almost
ceases.
95Time-temperature-transformation diagrams for
thermosets resins
- Important concepts
- Devitrification
- Tg decreases through isothermal temperature of
cure due to degradation - degradation leads to decrosslink and formation of
plasticizing materials - Char or vitrification
- due to increase of crosslink and volatilization
of low molecular weight plasticizing materials
96Time-temperature-transformation diagrams for
thermosets resins
- Important concepts
- Three critical temperatures
- Tg? - Tg of cured system
- gelTg - Tg of gel
- Tgo - Tg of reactants
97Time-temperature-transformation diagrams for
thermosets resins
- Discussion
- Ungelled glassy state is good for commercial
molding compounds - Tgo gt Tprocessing, processed as solid
- Tgo lt Tprocessing, processed as liquid
- Store temperature lt gelTg to avoid gelation
- Resin fully cured when Tg Tg?
- Tg gt Tcure about 40ºC
- Full cure is achieved most readily by cure at T gt
Tg? and slowly at T lt Tg?.
98Unsaturated polyester
- Reading assignment
- Mallick, P.K., Fiber Reinforced Composites .
Materials, Manufacturing and Design, pp56-64. - Resin
- Products of condensation polymerization of
diacids and diols - e.g. Maleic anhydride and ethylene glycol
- Strictly alternating polymers of the type
A-B-A-B-A-B - At least one of the monomers is ethylenically
unsaturated
99Unsaturated polyester
100Unsaturated polyester
101Unsaturated polyester
- Cross-linking agent
- Reactive solvent of the resin e.g. styrene
- Addition polymerization with the resin molecules
initiator needed, e.g. peroxide - Application of heat to decompose the initiator to
start addition polymerization - an accelerator may be added to increase the
decomposition rate of the initiator.
102Unsaturated polyester
103Unsaturated polyester
- Factors to control properties
- Cross-linking density
- addition of saturated diacids as part of the
monomer for the resin e.g phthalic anhydrid,
isophthalic acid and terephthalic acid - as ratio of saturated acids to unsaturated acids
increases, strength and elongation increase while
HDT decreases
104Unsaturated polyester
- Factors controlling properties
- Type of acids
- Terephthalic acids provide higher HDT than the
other two acids due to better packing of
molecules - nonaromatic acid adipic acid HOOC(CH2)4COOH,
lowers stiffness - Resin microstructure
- local extremely high density of cross-links.
- Type of diols
- larger diol monomer diethylene glycol
- bulky side groups
105Unsaturated polyester
- Factors to control properties
- Type of crosslinking agent
- amount of styrene more styrene increases the
distance of the space of neighboring polyester
molecules ? lower modulus - Excessive styrene self-polymerization ?
formation of polystyrene ? polystyrene-like
properties
106Unsaturated polyester
- Advantages
- Low viscosity
- Fast cure
- Low cost
- Disadvantages
- lower properties than epoxy
- large mold shrinkage ? sink marks
- an incompatible thermoplastic mixed into the
resin to form a dispersed phase in the resin ?
low profile system
107Vinyl ester
- Resin
- Products of addition polymerization of epoxy
resin and an unsaturated carboxylic acid (vinyl) - unsaturated CC bonds are at the end of a vinyl
ester molecule ? fewer cross-links ? more
flexible - Cross-linking agent
- The polymer is dissolved in styrene
- Addition polymerization to form cross-links
- Formation of a gigantic molecule
- Similar curing reaction as unsaturated polyester
resin
108Vinyl ester
109Vinyl ester
110Vinyl ester
- Advantages
- epoxy-like
- excellent chemical resistance
- high tensile strength
- polyester-like
- Low viscosity
- Fast curing
- less expensive
- good adhesion to glass fibers due to existence of
-OH - Disadvantages
- Large volumetric shrinkage (5 10 )
111Vinyl ester
112Advantages of thermosetting resins
- High strength and modulus.
- Less creep and stress relaxation
- Good resistance to heat and chemicals
- Better wet-out between fibers and matrix due to
low viscosity before cross-linking
113Disadvantages of thermosetting resins
- Limited storage life
- Long time to cure
- Low strain to failure
- Low impact resistance
- Large shrinkage on curing
114Thermoplastic matrices
- Reading assignment
- Mallick, P.K., Fiber Reinforced Composites .
Materials, Manufacturing and Design, section 2.4
pp 64-69. - Types
- Conventional no chemical reaction during
processing - Semi-crystalline
- Liquid crystal
- Amorphous
- Pseudothermoplastics molecular weight increase
and expelling volatiles
115Thermoplastic matrices
- examples
- Conventional
- Nylon
- Polyethylene
- Polypropylene
- Polycarbonate
- Polyester
- PMMA
116Thermoplastic matrices
117Thermoplastic matrices
- examples
- Advanced (e.g.)
- Polyimide
118Thermoplastic matrices
119Thermoplastic matrices
- Main descriptors
- Linear
- Repeatedly meltable
- Properties and advantages of thermoplastic
matrices - High failure strain
- High impact resistance
- Unlimited storage life at room temperature
- Short fabrication time
- Postformability (thermoforming)
- Ease of repair by welding, solvent bonding
- Ease of handling (no tackiness)
120Thermoplastic matrices
121Disadvantages of thermoplastic matrices
- High melt or solution viscosity (high MW)
- Difficult to mix them with fibers
- Relatively low creep resistance
- Low heat resistance for conventional
thermoplastics
122Metal Matrices
- Examples
- Al, Ti, Mg, Cu and Super alloys
- Reinforcements
- Fibers boron, carbon, metal wires
- Whiskers
- Particulate
123Metal Matrices
- Fiber matrix interaction
- Fiber and matrix mutually nonreactive and
insoluble - Fiber and matrix mutually nonreactive but soluble
- Fiber and matrix react to form compounds at
interface
124Metal Matrices
- Advantage of metal matrix composites (MMC)
- Versus unreinforced metals
- higher strength to density ratio
- better properties at elevated temperature
- lower coefficient of thermal expansion
- better wear characteristics
- better creep performance
125Metal Matrices
- Advantage of MMC
- Versus polymeric matrix
- better properties at elevated temperature
- higher transverse stiffness and strength
- moisture insensitivity
- higher electrical and thermal conductivity
- better radiation resistance
- less outgassing contamination
126Metal Matrices
- Disadvantage of MMC
- higher cost
- high processing temperature
- relatively immature technology
- complex and expensive fabrication methods with
continuous fiber reinforcements - high specific gravity compared with polymer
- corrosion at fiber matrix interface (high
affiliation to oxygen) - limited service experience
127Ceramic Matrices
- Glass ceramics
- glass forming oxides, e.g. Borosilicates and
aluminosilicates - semi-crystalline with lower softening temperature
- Conventional ceramics
- SiC, Si3N4, Al2O3, ZrO2
- fully crystalline
- Cement and concrete
- Carbon/carbon
128Ceramic Matrices
- Increased toughness through deflected crack
propagation on fiber/matrix interface. - Example Carbon/carbon composites