Introduction to Composite Materials

Overview of Composite Materials

• Composite materials are engineered materials that consist of two or more distinct constituent materials, which work together to produce a material with improved properties.
• These materials are important in engineering because they offer a unique combination of properties that cannot be achieved by a single material.

Classification of Engineering Materials

• Materials can be classified into four main categories: metals, polymers, ceramics, and composites.
• Each category has its own unique properties and applications.

Properties of Materials

• Materials have various properties, including mechanical, thermal, electrical, and chemical properties.
• These properties determine the suitability of a material for a specific application.

Selection of Materials for Engineering Applications

• Material selection is based on several factors, including material properties, environmental impact, recycling potential, manufacturing requirements, cost, and availability.

Concept of Composite Materials

• Composite materials consist of two or more distinct constituent materials, which work together to produce a material with improved properties.
• The constituent materials are typically referred to as the matrix and the reinforcement.

Types of Composite Materials

• Metal matrix composites: consist of a metal matrix reinforced with particles, fibers, or whiskers.
• Ceramic matrix composites: consist of a ceramic matrix reinforced with carbon fibers, silicon carbide fibers, or ceramic fibers.

Applications of Composite Materials

• Medical devices: composite materials are used in medical devices due to their characteristics, such as being lighter, stronger, durable, radiolucent, and biocompatible.

Markets and Composites Industry

• The global composite market size is projected to reach USD 139.5 billion by 2025.
• The aerospace industry is currently the largest consumer of composite materials, accounting for over 50% of the market share.
• Key players in the composites industry include Hexcel Corporation, Owens Corning, Teijin Limited, SGL Carbon, Toray Industries, Inc, and DowAksa.

Manufacturing of Composite Materials

• Manufacturing processes for composite materials include hand layup, filament winding, resin transfer molding, pultrusion, and vacuum infusion.
• Challenges in manufacturing composite materials include variability, specialized equipment and expertise, complex geometry, brittle characteristics for secondary operations, and environmental issues.

Trends and Future Outlook for the Composites Industry

• Sustainability, fuel efficiency, and emissions regulations are driving the growth of the composites industry.
• Additive manufacturing and digitalization are also expected to play a significant role in the industry's future.