Course Code:EBB 337 Course Code:EBB 337 Course Title:Advanced Materials and Composites Course Title:Advanced Materials and Composites Course Unit:3 Course Unit:3 Type of Course:Core Type of Course:Core Name of academics:Dr. Mariatti Jaafar Name of academics:Dr. Mariatti Jaafar Dr. Ahmad Azmin Mohamed Dr. Ahmad Azmin Mohamed Dr. Zuhailawati Hussin Dr. Zuhailawati Hussin (6) Contribution of Assessment:70% final examination & 30% course work (15% Test and 15% Assignment/PBL) (6) Contribution of Assessment:70% final examination & 30% course work (15% Test and 15% Assignment/PBL)

Course Objectives/Course Outcomes (CO) 1. To classify different types of advanced composite materials 1. To classify different types of advanced composite materials 2. To select and justify a suitable advanced composite materials for specific applications 2. To select and justify a suitable advanced composite materials for specific applications 3. To propose a suitable fabrication technique of advanced composite materials for specific applications 3. To propose a suitable fabrication technique of advanced composite materials for specific applications 4. To apply suitable theory to estimate the properties of the advanced composite materials 4. To apply suitable theory to estimate the properties of the advanced composite materials

EBB 337 (Advanced Materials & Composites) Topic Contents Introduction to composite materials (Definition and classification of composite materials, natural composites, the benefit of composites) Introduction to composite materials (Types of matrix (natural and synthetic), types of reinforcement (natural and synthetic), factors which determine properties)

Reinforcement-matrix interface (Wettability, Interfacial bonding, methods to measure bond strength) Polymer matrix composites (Introduction, types of polymer matrices (thermoplastics, thermoset & rubber), processing of PMC- Hand lay-up, spray-up moulding methods (match die moulding, bag moulding method, vacuum bagging, pressure bagging, RTM), pultrusion, filament winding) Polymer matrix composites (Some commercial PMCs- epoxy and polyester matrix composites, PEEK matrix composites, rubber matrix composites, etc.)

References R.F. Gibson, Principles of Composite Materials Mechanics, McGraw Hill, Inc, R.F. Gibson, Principles of Composite Materials Mechanics, McGraw Hill, Inc, F.L. Matthews, R.D. Rawlings, Composite Materials; Engineering & Science, Chapman & Hall, F.L. Matthews, R.D. Rawlings, Composite Materials; Engineering & Science, Chapman & Hall, R.P Sheldon, Composite Polymeric Materials, Applied Science Publisher, 1982 R.P Sheldon, Composite Polymeric Materials, Applied Science Publisher, 1982 S. C. Sharma, Composite Materials, Narosa Publishing House, 2000 S. C. Sharma, Composite Materials, Narosa Publishing House, 2000

Test 1 – 16 Jan (Friday) Test 1 – 16 Jan (Friday) Short Assignment (not more than 5 pages;2 in a group)- due date 9 Jan Short Assignment (not more than 5 pages;2 in a group)- due date 9 Jan Find an article from Journal on the following titles; Find an article from Journal on the following titles; 1) Nanoparticles filled Polymer matrix composites for food packaging applications 1) Nanoparticles filled Polymer matrix composites for food packaging applications 2) Nanoparticles filled Polymer matrix composites for electronic packaging applications 2) Nanoparticles filled Polymer matrix composites for electronic packaging applications 3) Natural fiber reinforced Polymer matrix composites for construction or automotive applications 3) Natural fiber reinforced Polymer matrix composites for construction or automotive applications 4) Synthetic fiber reinforced Polymer matrix composites for aerospace applications 4) Synthetic fiber reinforced Polymer matrix composites for aerospace applications 5) Particulate filler filled Polymer matrix composites for medical applications 5) Particulate filler filled Polymer matrix composites for medical applications

Short Assignment Summarize the followings; Summarize the followings; Materials used (what is the matrix, reinforcement/filler, etc) Materials used (what is the matrix, reinforcement/filler, etc) Processing involved (hand lay-up, vacuum technique, injection molding, etc.) Processing involved (hand lay-up, vacuum technique, injection molding, etc.) Properties of composites measured, relate the properties of composites compared to monolithic materials Properties of composites measured, relate the properties of composites compared to monolithic materials

Composites vs. monolithic materials

What is Composites? Combination of 2 or more materials Combination of 2 or more materials Each of the materials must exist more than 5% Each of the materials must exist more than 5% Presence of interphase Presence of interphase The properties shown by the composite materials are differed from the initial materials The properties shown by the composite materials are differed from the initial materials Can be produced by various processing techniques Can be produced by various processing techniques Composite materials- a new emerging class of materials to overcome a current limits of monolithic of conventional materials

Constituents of composite materials 1.Matrix phase Continuous phase, the primary phase. It holds the dispersed phase and shares a load with it. 2. Dispersed (reinforcing) phase The second phase (or phases) is imbedded in the matrix in a continuous/discontinuous form. Dispersed phase is usually stronger than the matrix, therefore it is sometimes called reinforcing phase. 3. Interface Zone across which matrix and reinforcing phases interact (chemical, physical, mechanical)

Matrix: Function however the distribution of loads depends on the interfacial bondings

Reinforcement: Function

Reinforcement: Function depends on matrix Reinforcement: Function depends on matrix Metal matrix: to increase the hardness and creep resistance at high temp. Metal matrix: to increase the hardness and creep resistance at high temp. Polymer matrix: to improve stiffness, strength and toughness Polymer matrix: to improve stiffness, strength and toughness Ceramic matrix: to improve toughness Ceramic matrix: to improve toughness

Reinforcement can be in the form of: Continuous fiber Continuous fiber Organic fiber- i.e. Kevlar, polyethylene Organic fiber- i.e. Kevlar, polyethylene Inorganic fiber- i.e. glass, alumina, carbon Inorganic fiber- i.e. glass, alumina, carbon Natural fiber- i.e. asbestos, jute, silk Natural fiber- i.e. asbestos, jute, silk Short fiber Short fiber whiskers whiskers Particle Particle Wire Wire

Interface: Function To transfer the stress from matrix to reinforcement To transfer the stress from matrix to reinforcement Sometimes surface treatment is carried out to achieve the required bonding to the matrix

Interfaces & Interphases Figure 1.2 Figure 1.2

Types of matrix (natural and synthetic) Natural Natural Silica sand, limestone (CaCO3), talc, etc Silica sand, limestone (CaCO3), talc, etc Starch, epoxy based on soy bean, chitosan, etc Starch, epoxy based on soy bean, chitosan, etc Synthetic Synthetic Fumed silica, fused silica, glass, etc Fumed silica, fused silica, glass, etc Epoxy, polyester, PP, PE, etc Epoxy, polyester, PP, PE, etc

Types of reinforcement (natural and synthetic) Natural Natural Silica sand, limestone (CaCO3), talc, etc Silica sand, limestone (CaCO3), talc, etc Natural fibers, wood, etc Natural fibers, wood, etc Synthetic Synthetic Glass fiber, boron fibers, etc Glass fiber, boron fibers, etc Fumed silica, fused silica, glass, etc Fumed silica, fused silica, glass, etc

Classifications of composites Matrix; PMC, MMC, CMC Matrix; PMC, MMC, CMC Function; electrical & structure Function; electrical & structure Geometry of reinforcements; fiber composites & particulate composites Geometry of reinforcements; fiber composites & particulate composites

Classification based on Geometry of reinforcement Composite materials Fiber- composites Particulate- composites Random orientation Uni -directional Random orientation Uni- directional Two- directional

Examples of composites a)Particulate & random b)Discontinuous fibers & unidirectional c)Discontinuous fibers & random d)Continuous fibers & unidirectional

Classification based on Matrices Composite materials Matrices Polymer Matrix Composites (PMC) Metal Matrix Composites MMC) Ceramic Matrix Composites (CMC) ThermosetThermoplasticRubber

Widely used- ease of processing & lightweight Widely used- ease of processing & lightweight

Metal Matrix Composites (MMC) Generate wide interest in research Generate wide interest in research Not as widely use as PMC Not as widely use as PMC Higher strength, stiffness & fracture toughness Higher strength, stiffness & fracture toughness Can withstand elevated temperature in corrosive environment than PMC Can withstand elevated temperature in corrosive environment than PMC Most metal and alloy can be used as matrices Most metal and alloy can be used as matrices

Ceramic Matrix Composites (CMC) Able to withstand high temperature (>1649ºC) & brittle Able to withstand high temperature (>1649ºC) & brittle Used in aeronautics, military, etc Used in aeronautics, military, etc Carbon and glass are common matrix used in CMC Carbon and glass are common matrix used in CMC

Natural Composites Wood Wood Consists of cellulose, hemiselulose & lignin Consists of cellulose, hemiselulose & lignin Cellulose- the strongest component, 65% unidirectional alignment Cellulose- the strongest component, 65% unidirectional alignment Lignin behave as adhesive, tighten the wood components Lignin behave as adhesive, tighten the wood components

Bone Bone Example; hydroxyapatite reinforced collagen composites Example; hydroxyapatite reinforced collagen composites Natural Composites

Pole (Construction Industry) Traditional wood→steel→concrete→pol ymer composite (made of layers of glass fabric + resins) Traditional wood→steel→concrete→pol ymer composite (made of layers of glass fabric + resins) Advantages of Polymer Composites Advantages of Polymer Composites 1) won't rust, or corrode 2)require no preservatives 3) light-weight, lighter than aluminum, wood, steel or concrete. 4) the lowest possible total installed cost

Modern vaulting poles H ere is an example of a vaulting pole made from glass fibre reinforced polymer (GFRP) composites and carbon fibre reinforced polymer (CFRP) composites

Benefits of Composites??? Improved properties (thermal, mechanical, electrical, etc) Improved properties (thermal, mechanical, electrical, etc) Many end-applications Many end-applications

Properties of composites depend on Amount of phase Amount of phase - Amount/proportion (can be expressed in weight fraction (Wf) or volume fraction (Vf))of phases strongly influence the properties of composite materials. X c = X f V f + X m (1 - V f ) - Rule of Mixture X c = Properties of composites X f = Properties of fiber X m = Properties of matrix

Voids Free volume Free volume Gas emission leads to voids in the final product Gas emission leads to voids in the final product In composites- Voids exist in the matrix, interface and in between fiber & fiber In composites- Voids exist in the matrix, interface and in between fiber & fiber Voids create stress concentration points- influence the properties of the composites Voids create stress concentration points- influence the properties of the composites

Geometry of dispersed phase (particle size, distribution, orientation) Shape of dispersed phase (particle- spherical or irregular, flaky, whiskers, etc) Shape of dispersed phase (particle- spherical or irregular, flaky, whiskers, etc) Particle/fiber size ( fiber- short, long, continuous); particle (nano or micron size) Particle/fiber size ( fiber- short, long, continuous); particle (nano or micron size) Orientation of fiber/particle (unidirection, bi- directions, many directions)- influence isotropic dan an- isotropic properties Orientation of fiber/particle (unidirection, bi- directions, many directions)- influence isotropic dan an- isotropic properties Dictribution of dispersed phase (homogenus/uniform, inhomogenus) Dictribution of dispersed phase (homogenus/uniform, inhomogenus)

Examples of different composite geometrical arrangements

Processing technique and parameters Influence final product, selection of correct raw materials, void content, etc Influence final product, selection of correct raw materials, void content, etc