Composite Materials: History & Classification PDF

FAMILY OF COMPOSITES SUMMARY mechanism — parCculate and dispersion- strengthened. HISTORY AND CLASSIFICATION OF COMPOSITE 1. ParHculate: Coarse parCcles like tungsten MATERIALS...

FAMILY OF COMPOSITES SUMMARY mechanism — parCculate and dispersion- strengthened. HISTORY AND CLASSIFICATION OF COMPOSITE 1. ParHculate: Coarse parCcles like tungsten MATERIALS carbide embedded in metals for cuYng tools. Ancient Times: 2. Dispersion-Strengthened: Fine parCcles improve properCes at the atomic level, such as -3400 B.C.: Mesopotamians glued wood strips at Thoria-dispersed nickel alloys. different angles to create plywood. Examples: Concrete, reinforced concrete, and - 2181–2055 B.C.: EgypCans used Cartonnage some metal matrix composites. and layers of linen or papyrus soaked in plaster for death masks. FIBER-REINFORCED COMPOSITES - 1500 B.C.: EgypCans and Mesopotamians used straw to reinforce mud bricks, poIery, and boats. - Fiber-reinforced composites provide improved mechanical properCes such as strength, and - 25 B.C.: Roman cement described in ‘The Ten strength-to-weight raCo. It incorporates strong, Books on Architecture’ resembled modern sCff but briIle fibers into a so\er, ducCle matrix. Portland cement. The matrix acts as a medium to transfer the load 1200s to Modern Era: to the fibers that do the majority of heavy li\ing. - 1200 A.D.: Mongols invented composite bows They are further classified as either conHnuous made of wood, bamboo, caIle tendons, and silk. or disconHnuous fibers. - 1800s: SyntheCc resins like Bakelite emerged 1. ConHnuous Fibers: Long fibers oriented during the chemical revoluCon. uniformly for customized mechanical properCes. - 1900s–1950s: Advances in plasCcs and 2. DisconHnuous Fibers: manufacturing led to widespread composite use - Aligned: High strength in specific direcCons. in aerospace and other fields. - Randomly Oriented: Uniform properCes but - 1990s to Present: Composites became lower peak strength. mainstream in construcCon, automoCve, aerospace, and medical industries. Examples: Carbon fiber-reinforced polymers, fiberglass, and carbon composite materials. CLASSIFICATION OF COMPOSITES STRUCTURAL COMPOSITES Matrix Types: 1. Laminar: Layers of materials like metals or o Ceramic, polymer, metal, fibers cemented together for structural integrity. thermoplasCc, and thermoset. Reinforcement Types: 2. Sandwich Structures: Thin layers joined to lightweight cores for rigidity and strength in 1. ParCcle-Reinforced: ParCculate or dispersion- aerospace and construcCon. strengthened. PRACTICAL COMPOSITE SYSTEMS 2. Fiber-Reinforced: ConCnuous or disconCnuous. - PracCcal composite systems are composite materials applied in industrial, structural, 3. Structural: Laminates and sandwich and consumer products to enhance composites. performance characterisCcs like strength, durability, lightweight, and corrosion Matrix Phase: The conCnuous phase resistance. binds and transfers loads. Dispersed Phase: The reinforcing phase 1. Sustainability Focus: IncorporaCng provides strength and rigidity. renewable fibers like flax and recyclable resins to reduce environmental impact. PARTICLE-REINFORCED COMPOSITES ApplicaCons include automoCve panels and packaging. - These are one of the most widely used classes 2. Hybrid Composites: Combining materials of composite structures due to their ease of like carbon and glass fibers for strength, availability while being economical. They can be durability, and flexibility. Used in bicycles, further disCnguished based on the strengthening body armor, and aerospace. PRESENTATION OF COMPOSITE MATERIAL o Reinforcement (OpConal): Steel PRODUCTS rebar or fiber materials may be added for increased tensile - The composite manufacturing process strength. varies according to materials and desired o Pouring and Shaping: The output for the final composite material. The concrete is poured into forms or three main composite manufacturing molds for the desired shape. processes are open molding, closed o Curing: Concrete undergoes a molding, and cast polymer molding. Then curing process, where it is kept there are a variety of processing methods moist to gain strength over Cme. within each of these. Which composite Types manufacturing methods are used is a o Precast Concrete: Poured and decision made according to the material, cured in a factory, then design, and applicaCon of the final transported to the site. composite. o Cast-in-Place Concrete: Poured Fiberglass: directly at the site. Final Products: Used in construcCon ComposiHon: Glass fibers within resin. elements like slabs, walls, and ProperHes: High strength-to-weight infrastructure. raCo, corrosion resistance, and insulaCon. Linoleum: ApplicaHons: Boats, automoCve parts, ComposiHon: Linseed oil, wood flour, and insulaCon. cork dust, and pigments. Process Steps: ProperHes: Durable, biodegradable, and o Glass Fiber ProducHon: Glass is anCmicrobial. melted at high temperatures ApplicaHons: ResidenCal and healthcare and extruded into thin fibers. flooring. o Fiber CoaHng: Fibers are treated Process Steps: with a coaCng (sizing) to o Mixing Ingredients: Linseed oil, improve adhesion with resin. wood flour, cork dust, and o Laying Up and Molding: Fibers pigments are mixed to create a are laid in molds and combined base. with resin (usually polyester or o Oxidizing Linseed Oil: The oil is epoxy). oxidized to form a thick, sCcky o Curing: The resin is cured by material called linoleum applying heat or a chemical cement. catalyst, solidifying the shape. o Spreading on Jute Backing: The Types linoleum cement is spread over o Hand Lay-Up: Layers of fiber are a jute backing and rolled out. manually applied, then resin is o Curing: The material is placed in added. drying rooms to cure for several o Spray-Up: Chopped fibers and weeks, enhancing flexibility and resin are sprayed together for durability. faster producCon. Final Products: Strong, lightweight Fiber Cement: structures such as boat hulls, panels, and ComposiHon: Cement and cellulose parts. fibers. Concrete: ProperHes: Durable, fire-resistant, and weatherproof. ComposiHon: Cement, sand, aggregates, ApplicaHons: Roofing, exterior cladding. opConally reinforced with steel rebar. Process Steps: ProperHes: High compressive strength o Mixing Ingredients: Cement, and durability. sand, water, and cellulose fibers ApplicaHons: Buildings, bridges, roads. are mixed to form a slurry. Process Steps: o Forming Sheets: The slurry is o Mixing Ingredients: Cement, poured into molds or rolled out sand, gravel (or other into thin sheets. aggregates), and water are o Curing: Sheets undergo a curing mixed. process, o\en involving steam  or autoclaving, to harden and strengthen them. o CuUng and Finishing: Sheets are cut to size and may be coated or painted for specific applicaCons. Types o Textured Fiber Cement: Designed to mimic natural materials like wood or stone. o Smooth Fiber Cement: Flat panels with a sleek, modern appearance. Final Products: Lightweight, durable panels or boards used in construcCon. Plywood: ComposiHon: Thin wood veneers bonded with adhesive. ProperHes: Resistant to spliYng, versaCle, and strong. ApplicaHons: Furniture, walls, and roofing. Process Steps: o Log PreparaHon: Logs are soaked in water or steamed to so\en them. o Veneer Peeling: A lathe peels the log into thin sheets. o Drying and Grading: Veneers are dried and graded based on quality. o Gluing and Stacking: Adhesive is applied, and veneers are stacked with alternaCng grain direcCons. o Pressing: The stack is subjected to high pressure and heat to cure the adhesive. o Trimming and Finishing: Panels are cut to size and may be sanded or coated for specific purposes. Types o SoWwood Plywood: Made from coniferous trees like pine; used for construcCon. o Hardwood Plywood: Made from hardwood species like birch; used in furniture and cabinetry. o Exterior Plywood: Treated to resist moisture; suitable for outdoor use. Final Products: VersaCle panels that cater to a variety of structural and decoraCve applicaCons.