1. APPLICATIONS OF COMPOSITE MATERIALS- OVERVIEW
Presented by:
Dr. M.S. STARVIN M.E.,Ph.D Asst.Professor
University College of Engineering Nagercoil
Anna University of Technology Tirunelveli
TamilNadu
India

2. INTRODUCTION
Two inherently different materials combined together to produce a material with properties that exceed the constituent materials.
A combination of two or more materials (reinforcement, resin, filler, etc.), differing in form or composition on a macroscale. The constituents retain their identities, i.e.., they do not dissolve or merge into each other, although they act in concert. Normally, the components can be physically identified and exhibit an interface between each other.
High Strength
Light Weight
Design Flexibility
Low maintenance
Extended Service Life

3. ADVANTAGES Higher Specific Strength (strength-to-weight ratio)
Composites have a higher specific strength than many other materials. A distinct advantage of composites over other materials is the ability to use many combinations of resins and reinforcements, and therefore custom tailor the mechanical and physical properties of a structure.
Design flexibility
Composites have an advantage over other materials because they can be molded into complex shapes at relatively low cost. This gives designers the freedom to create any shape or configuration. Boats are a good example of the success of composites

4. ADVANTAGES Corrosion Resistance
Composites products provide long-term resistance to severe chemical and temperature environments. Composites are the material of choice for outdoor exposure, chemical handling applications, and severe environment service.
Durability
Composite products and structures have an exceedingly long life span. Coupled with low maintenance requirements, the longevity of composites is a benefit in critical applications. In a half-century of composites development, well-designed composite structures have yet to wear out.
In 1947 the U.S. Coast Guard built a series of forty-foot patrol boats, using polyester resin and glass fiber. These boats were used until the early 1970s when they were taken out of service because the design was outdated. Extensive testing was done on the laminates after decommissioning, and it was found that only 2-3% of the original strength was lost after twenty-five years of hard service.

5. dISADVANTAGES Composites are heterogeneous
Composites are highly anisotropic
Composites materials are difficult to inspect with conventional ultrasonic, eddy current and visual NDI methods such as radiography.
debonding face/core in the sandwich structure
Reuse and disposal may be difficult.
Matrix is subject to environmental degradation.

6. Major Constituents FIBER Principle Load carrying member
Main constituent and they occupy largest volume fraction
Diameter of a single fiber is about 10 microns
They may be continuous or discontinuous in length.
MATRIX
Holds the fibres together.
To transfer stress between reinforcing fibers and to protect them from mechanical and environmental damage
FILLERS
COUPLING AGENTS
COLORANTS

7. Reinforcing fibers
Glass – most common and the least expensive, high strength, low stiffness and high density. GFRP consists 30-60% glass fibers by volume.
Graphite (99% carbon) or Carbon – more expensive than glass fibers, but lower density and higher stiffness with high strength. The composite is called carbon-fiber reinforced plastic (CFRP).
Boron– boron fibers consist of boron deposited on tungsten fibers, high strength and stiffness in tension and compression, resistance to high temperature, but they are heavy and expensive.
Aramids (Kevlar)– highest specific strength, toughest fiber, undergoes plastic deformation before fracture, but absorbs moisture, and is expensive.

8. TYPES OF GLASS FIBER E-Glass –E stands for Electrical
*high strength
*good water resistance
*good electric insulating properties
*low stiffness
S-Glass –S stands for high Silica content
*High thermal expansion coefficient
*High fatigue strength
C-Glass –C stands for Corrosion
*Used in Chemical applications
*Storage tanks
R-Glass –R stands for Rigid
*Structural applications
D-Glass –D stands for Dielectric
* Low dielectric constants
A-Glass –A Stands for Appearance
*To improve surface appearance
*For ornamental works
E-CR Glass –E-CR stands for Electrical and Corrosion Resistance
AR Glass –AR stands for Alkali Resistance
About 90% of all composites produced are comprised of glass fiber and either polyester or vinylester resin. Composites are broadly known as reinforced plastics

9. AL ALLOY VS CARBON/EPOXY
Aluminum Alloy
(7075-T6)
Carbon /Epoxy
Density
2800 kg/m3
1580 kg/m3
Tensile Strength
570 Mpa
1830 MPa
Strength Weight ratio
0.204
1.158

10. Application of Composites in Aircraft Industry
20% more fuel efficiency and 35,000 lbs. lighter

11. Ken Youssefi
Mechanical Engineering Dept.

12. Space Applications
space shuttles: mid-fuselage truss structure (boron fiber-reinforced aluminum tubes),
payload bay door (sandwich laminate of carbon fiber-reinforced epoxy face sheets and aluminum honeycomb core),
remote manipulator arm (ultrahigh-modulus carbon fiber-reinforced epoxy tube)
pressure vessels (Kevlar 49 fiber-reinforced epoxy).
The temperature in space may vary between -100C and 100C, it is critically important that the support structure be dimensionally stable; otherwise, large
changes in the relative positions of mirrors or lenses due to either thermal expansion or distortion may cause problems in focusing the telescope.
Carbon fiber-reinforced epoxy tubes are used in building truss structures for
Low earth orbit (LEO) satellites and interplanetary satellites. These truss structures support optical benches, solar array panels, antenna reflectors, and othermodules.

13. Automotive Applications
Body components
Exterior body components , such as the hood or door panels,
require high stiffness and damage tolerance (dent resistance ) as well as a
‘‘Class A’’ surface finish for appearance.
Chassis components,
Uni leaf E-glass fiber-reinforced epoxy springs have been used to
replace multi leaf steel springs with as much as 80% weight reduction. Other
structural chassis components, such as drive shafts and road wheels, have been successfully tested in laboratories and proving grounds.
Engine Components
Fatigue loads at very high temperatures pose the greatest challenge in these applications. Development of high-temperature polymers as well as metal matrix or ceramic matrix composites would greatly enhance the potential for composite usage in this area.

14. TRANSPORTATION Vehicles Highway structures
E-Glass Fiber Used to Replace Leaf Spring, Body parts, drive shaft, springs

16. ARTIFICIAL LIMBS
The endoskeleton type of artificial limbs use more & more light weight composites with carbon or glass fibre and polymer matrix.
This below-the-knee endoskeleton limb consists of five parts: a FRP tubular structure fabricated by filament winding of glass fibre in epoxy matrix, top & bottom connectors made by injection moulding of glass filled nylon, a polyurethane foot with composite keel embedded in it and a polypropylene socket to accommodate the amputee stump. The socket made of polypropylene is patient specific and does not create any problems like pressure sores even for diabetic patients. The FRP tube connects the socket to the foot.

17. CONSTRUCTION

18. SPORTS-APPLICATIONS
archery equipment

19. CHEMICAL APPLICATIONS

20. Application of Composites
Lance Armstrong’s 2-lb. Trek bike, 2004 Tour de France
Pedestrian bridge in Denmark, 130 feet long (1997)
The stealth aircrafts is almost all made of carbon fiber-reinforced polymers. The stealth characteristics of these aircrafts are due to the use of carbon fibers, special
coatings, and other design features that reduce radar reflection and heat
radiation.
2007 Swedish Navy, Stealth (2005)
Ken Youssefi
Mechanical Engineering Dept.

21. Composites – Metal Matrix
The metal matrix composites offer higher modulus of elasticity, ductility, and resistance to elevated temperature than polymer matrix composites. But, they are heavier and more difficult to process

22. Composites – Ceramic Matrix
Ceramic matrix composites (CMC) are used in applications where resistance to high temperature and corrosive environment is desired. CMCs are strong and stiff but they lack toughness (ductility)
Matrix materials are usually silicon carbide, silicon nitride and aluminum oxide, and mullite (compound of aluminum, silicon and oxygen). They retain their strength up to 3000 oF.
Fiber materials used commonly are carbon and aluminum oxide. .
Applications are in jet and automobile engines, deep-see mining, cutting tools, dies and pressure vessels.

23. Query

24. Thank You
M.S.Starvin