Advanced Materials Ch4.ppt
Transcript of Advanced Materials Ch4.ppt
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COMPOSITES
Chapter 4
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Introduction A Composite material is a material system composed
of two or more macro constituents that differ in shapeand chemical composition and which are insoluble ineach other.
The history of composite materials dates back to early20th century. In 1940, fiber glass was first used toreinforce epoxy.
Applications: Aerospace industry Sporting Goods Industry Automotive Industry Home Appliance Industry
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Combination of two or more individual materials
Design goalObtain a more desirable combination of properties
(principle of combined action)e.g., low density and high strength
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Ancient Mud bricks-makingMaking bricks with straw
The earliest man-made compositematerials were straw and mudcombined to form bricks for buildingconstruction. Ancient brick-makingwas documented by Egyptian tombpaintings.
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https://wikicourses.wikispaces.com/Composite+materials+essay+%28HW+2%29
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https://www.youtube.com/watch?v=dbywZ4PJ3QA
Composites
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Classification of composites
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Composites consist of:
1. Combination of two or more materials Composite = matrix + fiber (filler):
• Matrix:
• material component that surrounds the fiber.
• Usually a ductile, or tough, material w/ low density
• Strength usually = 1/10 (or less) than that of fiber
• Examples include: thermoplastic or thermoset
• Thermoset most common (epoxy, pheneolic)
• Serves to hold the fiber (filler) in a favorable orientation.
• Fiber also known as reinforcing material aka Filler:
• Materials that are strong with low densities
• Examples include glass, carbon or particles.
2. Designed to display a combination of the best characteristics of each material i.e. fiberglass acquires strength from glass and flexibility from the polymer.
3. Matrix and filler bonded together (adhesive) or mechanically locked together!
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Terminology/Classification
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• Composite:-- Multiphase material that is artificially
made.
• Phase types:-- Matrix - is continuous-- Dispersed - is discontinuous and
surrounded by matrix
Adapted from Fig. 16.1(a), Callister & Rethwisch 8e.
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Composite Structural Organization: the design variations
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Terminology/Classification
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• Dispersed phase:-- Purpose:
MMC: increase σy (yield stress)
CMC: increase Kic (Fracture Toughness)
PMC: increase E, σy,.-- Types: particle, fiber, structural
• Matrix phase:-- Purposes are to:
- transfer stress to dispersed phase- protect dispersed phase from environment
-- Types: MMC, CMC, PMC
metal ceramic polymer
Reprinted with permission fromD. Hull and T.W. Clyne, An Introduction to Composite Materials, 2nd ed., Cambridge University Press, New York, 1996, Fig. 3.6, p. 47.
woven fibers
cross section view
0.5mm
0.5mm
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Matrix CompositesMatrix Materials: Polymer Matrix Composites PMC
There are two basic categories of polymer matrices: -Thermoplastics -Thermoset plastics
Roughly 95% of the composite market usesthermosetting plastics
Thermosetting plastics are polymerized in two ways: By adding a catalyst to the resin causing the resin to
‘cure’, basically one must measure and mix two parts ofthe resin and apply it before the resin cures
By heating the resin to it’s cure temperature
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Phenolic (phenols): good electrical properties,often used in circuit board applications
Epoxies: low solvent emission (fumes) uponcuring, low shrink rate upon polymerizationwhich produces a relatively residual stress-freebond with the reinforcement, it is the matrixmaterial that produces the highest strength andstiffness, often used in aerospace applications
Polyester (Polyester resin): most commonlyused resin, slightly weaker than epoxy but abouthalf the price, produces emission when curing,used in everything from boats to piping toCorvette bodies (combat ships).
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Common thermosetting plastics:
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
The reinforcement in a polymer matrix compositeprovides strength and stiffness that are lacking in thematrix.
The continuous reinforcing fibers of advancedcomposites are responsible for their high strength andstiffness.
The most important fibers in current use are glass,graphite, and aramid (Kevlar).
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Sanchez, Clément, et al. "Applications of advanced hybrid organic–inorganic nanomaterials: from laboratory to market." Chemical Society Reviews 40.2 (2011): 696-753.
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https://youtu.be/6Dc88exXGpQ
carbon fiber composite car parts
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Matrix CompositesMatrix Materials: Metal Matrix Composites MMC
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering 25
Sou
rce:
Bas
ics
of M
etal
Mat
rix C
ompo
site
s, K
arl U
lrich
Kai
ner
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering 26
Sou
rce:
Bas
ics
of M
etal
Mat
rix C
ompo
site
s, K
arl U
lrich
Kai
ner
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
MMC-Applications
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Applications of MMC in Automotive: Some automotive disc brakes use MMCs. Early Lotus Elise models used
aluminum MMC rotors, but they have less than optimal heat properties andLotus has since switched back to cast-iron.
Modern high-performance sport cars, such as those built by Porsche, use rotorsmade of carbon fiber within a silicon carbide matrix because of its high specificheat and thermal conductivity.
3M sells a preformed aluminum matrix insert for strengthening cast aluminumdisc brake calipers, allowing them to weigh as much as 50% less whileincreasing stiffness.
Ford offers a Metal Matrix Composite (MMC) driveshaft upgrade. The MMCdriveshaft is made of an aluminum matrix reinforced with boron carbide.
Honda has used aluminum metal matrix composite cylinder liners in some oftheir engines, including the B21A1, H22A and H23A, F20C and F22C, and theC32B used in the NSX.
Toyota has since used metal matrix composites in the Yamaha-designed 2ZZ-GE engine which is used in the later Lotus Lotus Elise S2 versions as well asToyota car models, including the eponymous Toyota Matrix.
Porsche also uses MMCs to reinforce the engine's cylinder sleeves in the Boxsterand 911.
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https://youtu.be/mjytampRzRM
Light Weight Metal Matrix Composite Brake Drum
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Matrix CompositesMatrix Materials: Metal Matrix Composites MMC
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GE tests GE9X engine with ceramic matrix composites.Ground testing is underway on a GEnx engine that contains lightweight, heat-resistant ceramic matrix composite (CMC) components.
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Composite Survey
Large-particle
Dispersion-strengthened
Particle-reinforced
Continuous(aligned)
Aligned Randomlyoriented
Discontinuous(short)
Fiber-reinforced
Laminates Sandwichpanels
Structural
Composites
Adapted from Fig. 16.2, Callister 7e.
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
• CMCs: Increased toughnessComposite Benefits
fiber-reinf
un-reinf
particle-reinfForce
Bend displacement
• PMCs: Increased E/ρ
E(GPa)
G=3E/8K=E
Density, ρ [mg/m3].1 .3 1 3 10 30
.01.11
10102103
metal/ metal alloys
polymers
PMCs
ceramics
Adapted from T.G. Nieh, "Creep rupture of a silicon-carbide reinforced aluminum composite", Metall. Trans. A Vol. 15(1), pp. 139-146, 1984. Used with permission.
• MMCs:Increasedcreepresistance
20 30 50 100 20010-10
10-8
10-6
10-4
6061 Al
6061 Al w/SiC whiskers σ(MPa)
εss (s-1)
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering 38
• Examples:Adapted from Fig. 10.19, Callister & Rethwisch 8e. (Fig. 10.19 is copyright United States Steel Corporation, 1971.)
- Spheroidite steel
matrix: ferrite (α)(ductile)
particles: cementite(Fe3C) (brittle)60 μm
Adapted from Fig. 16.4, Callister & Rethwisch 8e. (Fig. 16.4 is courtesy Carboloy Systems, Department, General Electric Company.)
- WC/Co cemented carbide
matrix: cobalt (ductile, tough)
particles: WC (brittle, hard):
600μmAdapted from Fig. 16.5, Callister & Rethwisch 8e. (Fig. 16.5 is courtesy Goodyear Tire and Rubber Company.)
- Automobile tire rubber
matrix: rubber (compliant)
particles: carbon black (stiff) 0.75μm
Particle-reinforced Fiber-reinforced Structural
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Classification: Particle-Reinforced
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Concrete – gravel + sand + cement + water- Why sand and gravel? Sand fills voids between gravel particles`
Reinforced concrete – Reinforce with steel rebar or remesh- increases strength - even if cement matrix is cracked
Pre-stressed concrete- Rebar/remesh placed under tension during setting of concrete - Release of tension after setting places concrete in a state of compression- To fracture concrete, applied tensile stress must exceed this
compressive stress
Particle-reinforced Fiber-reinforced Structural
threadedrod
nut
Post-tensioning – tighten nuts to place concrete under compression
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Classification: Fiber-Reinforced
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• Fibers very strong in tension– Provide significant strength improvement to the
composite– Ex: fiber-glass - continuous glass filaments in a
polymer matrix• Glass fibers
– strength and stiffness• Polymer matrix
– holds fibers in place – protects fiber surfaces– transfers load to fibers
Particle-reinforced Fiber-reinforced Structural
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• Critical fiber length for effective stiffening & strengthening:
• Ex: For fiberglass, common fiber length > 15 mm needed
Classification: Fiber-Reinforced (v)Particle-reinforced Fiber-reinforced Structural
c
f dτ
σ>2
length fiber
fiber diameter
shear strength offiber-matrix interface
fiber ultimate tensile strength
• For longer fibers, stress transference from matrix is more efficientShort, thick fibers:
c
f dτ
σ<2
length fiberLong, thin fibers:
Low fiber efficiency
c
f dτ
σ>2
length fiber
High fiber efficiency
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Benefits of Long Fiber Reinforced
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Composite Production MethodsPultrusion* Continuous fibers pulled through resin tank to impregnate fibers with thermosetting
resin Impregnated fibers pass through steel die that preforms to the desired shape Preformed stock passes through a curing die that is
precision machined to impart final shape heated to initiate curing of the resin matrix
Fig. 16.13, Callister & Rethwisch 8e.
*The term is a portmanteau word, combining "pull" and "extrusion".
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Filament Winding Continuous reinforcing fibers are accurately positioned in a predetermined pattern to
form a hollow (usually cylindrical) shape Fibers are fed through a resin bath to impregnate with thermosetting resin Impregnated fibers are continuously wound (typically automatically) onto a mandrel After appropriate number of layers added, curing is carried out either in an oven or at
room temperature The mandrel is removed to give the final product
Adapted from Fig. 16.15, Callister & Rethwisch 8e. [Fig. 16.15 is from N. L. Hancox, (Editor), Fibre Composite Hybrid Materials, The Macmillan Company, New York, 1981.]
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Pipe Fiber Reinforce Plastic Pipe
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Classification: Structural
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• Laminates --- stacked and bonded fiber-reinforced sheets
- stacking sequence: e.g., 0º/90º- benefit: balanced in-plane stiffness
Adapted from Fig. 16.16, Callister & Rethwisch 8e.
Particle-reinforced Fiber-reinforced Structural
• Sandwich panels-- honeycomb core between two facing sheets
- benefits: low density, large bending stiffness
honeycombadhesive layer
face sheet
Adapted from Fig. 16.18,Callister & Rethwisch 8e. (Fig. 16.18 is from Engineered MaterialsHandbook, Vol. 1, Composites, ASM International, Materials Park, OH, 1987.)
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Special Issue: Composites for Ultralight Vehicles
Jenna OwenUniversity of Texas at Austin
ElectroPhen, 2008
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Introduction Ultralight Strategy Materials Advanced Composites Hypercar Conclusion
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Current model and disadvantages Steel model has been seen for almost a century. Cars are very heavy due to the weight of the steel. Current vehicles are not energy efficient.
85% of energy input is lost 1% of energy is used to move the passengers
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Ultralight Strategy Mass decompounding is the key to an efficient
vehicle design.
Every 10% of weight reduction translates to a 7%increase in fuel economy.
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Materials Light Steel (25-30% lighter)
Hydroform tubing used to create the autobody. Laser welding allows thin steel to be welded to thicker
steel. Aluminum (40% lighter)
New types of alloys and production techniques tested Advanced Composites (50-67% lighter)
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Advanced Composites Composition
Polymers embedded into a “matrix of plastic” Composed of carbon, aramid, or similar fibers Composites durable, fatigue resistant, and reduce
noise and vibrations. Design
Materials formed into one unit or shell Aerodynamic drag reduced by 40-50% Rolling resistance reduced by 50%
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Advanced Composites Safety
Materials are 20 times as stiff, 4 times as tough, andcan handle temperatures twice as high.
Composites can absorb 5 times more energy than anequivalent amount of steel.
Cost Advanced composites are expensive 1-2 orders of magnitude fewer parts Simple assembly and few tools required
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Hypercar Incorporates ultralight technology along with a hybrid
electric drive system Travels 90-100 miles per gallon
Sundance Channel, 2008
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Conclusion Ultralight technology will increase the energy
efficiency of future vehicles.
Advanced composites create light, safe, durable, andsuperefficient vehicles.
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https://www.youtube.com/watch?v=KBZB3W7RG0M
Advanced Composite Technology Manufacturing
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Projects:1. Simulation of Injection Molding with Moldex 3D2. The Future use of composites materials in transport.3. Use of Shape memory alloys for Solar tracking
system.
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Literature Reviews: IUG Library:
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http://library.iugaza.edu.ps/fulltext.aspx
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
http://www.sciencedirect.com/
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
https://scholar.google.com
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Dr. Anwar Abu-Zarifa . Islamic University Gaza . Department of Industrial Engineering
Instructions for writing academic research Documentation ( Scientific paper, Research Proposal, technical Report)
Title of Research Project1. Abstract2. Motivation
Research Goals3. State-of-the-art
Literature Reviews4. Background
Ex: The Solar panel tracking system Ex: Shape memory alloys
5. Methodology6. Design and testing7. Conclusion8. References
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