Composite Materials and Their Processing

Glass fibers embedded in a plastic resin, used for boat hulls, car bodies, and aircraft components.

A composite material where carbon fibers are embedded in a carbon matrix. Extremely strong and lightweight, ideal for high-performance applications.

Used in fighter jet construction, combining graphite fibers with epoxy resin. Offers high strength and lightweight properties.

Metal matrix composites combine high-strength fibers (steel, boron, ceramics) with a molten metal (aluminum, titanium). They are known for their high strength and stiffness, especially at high temperatures.

This strong synthetic fiber is used for reinforcement in various applications, offering high tensile strength, low density, and flame retardant properties.

Used in automobile tires to improve strength and durability. These fibers can include nylon, rayon, steel, or Kevlar.

Using composites to create sports equipment like golf clubs, fishing rods, tennis rackets, and bicycle frames. The composites offer lightweight strength and performance.

A type of composite material where two or more different types of fibers are combined in a single matrix, resulting in improved properties compared to using a single fiber.

A type of hybrid composite where different fibers are arranged in alternating layers.

A type of hybrid composite where different fibers are mixed within the same layer of the material.

Reinforced composites with layers of different materials bonded together in a specific order, often with alternating grain directions.

The most common laminar composite, consisting of thin layers of wood veneer bonded together with adhesive, with alternating grain directions.

A material consisting of a thin, high-strength, high-density surface layer bonded to a low-density core to provide structural strength.

A type of hybrid composite reinforcing method that involves stitching together plies of different reinforcing materials to create a cohesive structure.

A thermoplastic matrix for use in high-temperature applications, often used in reinforced composites.

Unique weaving techniques used to create three-dimensional fabrics or fabric reinforcements with a specific shape, which offer improved strength and design flexibility in composites.

A process where two mold halves are clamped together, and a resin is injected into the cavity containing a reinforcing material. This technique is used for making small, non-load bearing parts.

A variant of RTM where the resin is mixed with reinforcing materials (like flake glass) before being injected into the mold. This method is known for its ability to avoid directional reinforcement.

A process where resin-impregnated fibers are pulled through a heated die, creating rods, tubes, and structural shapes with a constant cross-section.

A molding process where heated dies are used to cure the product. The material is placed in a pressing die and heat and pressure are applied to solidify the resin.

A type of molding process that uses Sheet Molding Compound (SMC). The SMC is cut to size and then molded into parts outside the press.

Coatings that are applied as a powder or frit and then fused to the surface of steel using heat. They are relatively brittle but offer complete protection against corrosion.

A type of ceramic coating on metal, often found on cookware and stoves.

Glazes are glassy ceramic coatings applied to a crystalline ceramic base, like tiles, for protection and decoration.

Coatings of specific materials like TiC, TiN, Al2O3, or HFN applied to a WC base.

Coatings of TiC and TiN applied to a HSS base.

Organic coatings that include paints, varnishes, enamels, and lacquers. These coatings protect the base material from corrosion and enhance its appearance.

A type of particulate composite that utilizes slurry (a mixture of materials suspended in liquid) for fabrication.

A method of creating composites by combining fibers with a matrix material. The process involves manipulating the size, form, and orientation of the fibers to achieve desired properties in the composite.

A manufacturing method for creating composite structures using an open mold, commonly used for lightweight and large-scale parts.

A technique for making fiber-reinforced composites by winding fibers onto a mandrel, creating strong, lightweight structures.

Prepregs are pre-impregnated with resin, forming a ready-to-mold sheet material. They are made by partially curing resin-impregnated rovings and mats, stored for later use, and then laid up in stacks that are heated and pressed to complete curing.

Bulk Molding Compounds (BMCs) are viscous compounds made by mixing thermosetting resins with chopped reinforcements and fillers. These are used for compression molding.

Sheet Molding Compounds (SMCs) are thin sheets consisting of chopped fibers and resin. They are processed to create large, sheet-like parts that offer benefits like light weight, corrosion resistance, and integrated color.

Thick Molding Compounds (TMCs) combine the lower cost of BMCs and the higher strength of SMCs. They are typically injected into molds and used in applications such as electrical components.

Hand Lay-up is a technique where layers of reinforcement material, either pre-impregnated or not, are placed manually on a mold. Resin is then applied to impregnate or coat the reinforcement, and the part is cured to solidify.

Wet Lay-up is a specific hand lay-up technique where resin-saturated reinforcements are placed directly into the mold. It's a way to create parts by applying resin-soaked material to the mold.

Bag Molding is a technique for molding reinforced plastics composites using a flexible cover (bag) over a rigid mold. This bag helps to apply pressure and heat.

A type of composite material where carbon fibers are embedded in a carbon matrix. It offers very high strength and stiffness, making it ideal for high-performance applications.

A composite material used extensively in fighter jet construction, it combines graphite fibers with epoxy resin. This creates parts like wings, fuselages, and control surfaces that are lightweight and strong.

A group of composites that incorporate strong fibers like stainless steel, boron, tungsten, molybdenum, graphite, and ceramic fibers within a molten metal matrix like aluminum, titanium, nickel, or cobalt. They are known for their high strength and stiffness, especially at elevated temperatures.

A strong, lightweight, synthetic fiber known for its high tensile strength and modulus of elasticity. It is also flame retardant and transparent to radio signals, making it ideal for military and aerospace applications.

Automotive tires are reinforced with fibers like nylon, rayon, steel, or Kevlar to increase their strength and durability.

A thermoplastic matrix used in high-temperature applications, often found in reinforced composites. It offers excellent chemical resistance and high mechanical strength.

Unique weaving techniques are employed to create three-dimensional fabrics or fabric reinforcements with a specific shape. This offers improved strength and design flexibility in composites.

The main benefit of using MMCs is their ability to withstand high operating temperatures and provide exceptional strength. This makes them ideal for applications like automotive parts, aircraft components, and even high-temperature engine parts.

Ceramic matrix composites (CMCs) are materials that combine a ceramic matrix with reinforcing fibers. These ceramics are known for their strength and ability to withstand high temperatures, while the fibers enhance toughness and resistance to cracking.

One of the main benefits of CMCs is their ability to resist high temperatures, making them perfect for applications like high-temperature engine components, pressure vessels, and even deep-sea mining equipment.

A hybrid MMC combines two or more types of reinforcing fibers within a single metal matrix. For example, an automotive engine piston made from a hybrid MMC may use fine particulates, ceramic whiskers, and continuous SiC or Carbon fibers within an aluminium matrix.

Los Alamos National Lab has developed a remarkable SiC-reinforced molybdenum disilicide intermetallic. This material is exceptionally strong, exceeding the strength of current intermetallic alloys by 15 times at temperatures above 1200°C.

The development stage for composites involves researching and creating new materials with even better properties. One example of this is the advanced bismaleimide resin matrix series, designed for use in high-temperature applications.

Toyota has created automotive engine pistons and connecting rods from hybrid MMCs. These materials are twice as strong as conventional SiC or Carbon-reinforced aluminum composite materials.

The fabrication of composite materials includes various techniques like filament winding, hand lay-up, and resin transfer molding. These methods are essential for combining the fibers and resin to create desired shapes and structures.

Two or more different types of fibers combined in a single matrix, resulting in enhanced properties compared to using a single fiber.

Structures with alternating layers of materials bonded together in a specific order.

The most common type of laminar composite; thin wood veneer layers bonded with adhesive, alternating grain directions.

A thin, high-strength, high-density surface layer bonded to a low-density core, for instance corrugated cardboard or polymer foam, to provide structural strength.

Combining fibers with a matrix material to create composites by manipulating fiber size, form, and orientation to achieve desired properties.

A closed pressure vessel used for curing resin or other operations under heat and pressure.

A technique for molding reinforced plastics where a flexible, transparent sheet covers the lay-up on the mold. Air is removed by vacuum before curing.

A process for molding reinforced plastics where a flexible bag is placed over the lay-up on the mold and compressed air creates pressure during curing.

A method for fabricating composite structures using a spray gun to deposit resin-impregnated chopped roving on the mold surface. This technique is efficient and cost-effective.

A technique where matched metal dies are used for molding composite structures. This method is used for high-volume production, close tolerances and superior surface quality.

A process where pre-impregnated resin-fiber sheets are manually placed on a mold and cured. This technique is commonly used for making parts like boats, tanks, and swimming pools.

This composite combines graphite fibers with epoxy resin for high strength and lightweight properties, often used in aircraft manufacturing.

A process where a pre-impregnated fiber bundle is pulled through a heated die, creating rods, tubes, and structural shapes with a constant cross-section.

A molding technique where heated dies press and cure the material to create a solid part.

A method where resin-impregnated fabric is placed on a mold and cured to create a composite structure.