Applications of Composites

P.S.SAMPATH
Department of Mechanical Engineering
KSR College of Technology
Tiruchengode-637215.
e-mail: [email protected]
 Contents
• Introduction
• Matrix Materials
• Reinforcement
• Manufacturing Techniques
• Industrial Applications
 What is a composite?

Composite, as its name suggests is a

combination of two or more dissimilar
materials.

The resultant composite will have properties

which are superior to those of the individual
components
 Are composites new materials?

No! Not at all.

The first composite was probably made during

Biblical time when man added chopped straw to
clay to make stronger bricks.

The iron-rod reinforced concrete, widely used in

modern buildings, is also an example of
composites.
 But what is new?

Polymer composites are

comparatively newer materials. As
the usage of polymers is increasing
day by day in all walks of life,
research is being carried out to
improve their properties to identify
newer applications.
What are the components present in a
Composite?
• A composite consists of a continuous
phase which is known as a MATRIX in
which a second component is Reinforced.
The second component is known as
REINFORCEMENT.
• There are many matrix and
reinforcement materials which are
widely used.
What are composite materials made
from?

Composite materials can also be put into

three main groups depending on their
matrix:
Polymer matrix composites (PMCs)
Metal matrix composites (MMCs)
Ceramic matrix composites (CMCs)
 Now let us discuss about the selection of
the components of the composites:

Matrix materials:
Thermosets: Polyesters, Epoxies, Phenolics, Silicones
and Urethanes.
General Purpose Polyesters–Cheaper materials.
Epoxy – Ease of making the composites.
Phenolics – High Temperature Resistance, Low smoke
evolution- preferred for metro train panels.
Silicones – Heat resistant- used in solar panels.
Thermoplastics: PVC; Polypropylene;
Polyethyleneterephathalate (PET);
Polyamides (nylons), Polyimide, Polyacrylates.

Reinforcements:
• Glass fibres, Carbon fibers, Kevlar fibres, Polyester
fibres, Nylon fibres, Acrylic fibres, natural fibres.
• Glass fibres: E-; C; S; Z; M and D- Glass fibres
E-Glass: Corrosion and Environmental resistance.
C-Glass: Higher Acid Resistance.
Z-Glass: Corrosion and Alkali resistant.
 PRINCIPAL FIBRES

Aramid fibres
e.g. Kevlar, Twaron
Carbon Fibres
Glass Fibres
Natural fibres
flax, hemp, jute, kenaf, sisal
Polyethylene fibres e.g. Dyneema,
Spectra
Surface treatments on fibres
 Typical benefits include:
• High strength , Light Weight
• Corrosion Resistance
• Excellent Chemical & Electrical Resistance
• Dimensional Stability, Low tooling cost
• Design Flexibility
• Excellent fatigue resistance
• Reduced maintenance and long life spans
METHODS OF PRODUCTION
• Hand lay-up Process
• Pultrusion
• Compression Moulding
• Resin Transfer Moulding
• Resin Injection Moulding
• Vacuum Bag Moulding
• Spray-up Technique
• Filament Winding
What products are made by the fibre
reinforced composites?
• Many products!
• A. Aircraft Industry:
Advanced Light Helicopters,
B1-Bombers; Light canard Research
Aircraft; Many Aircraft parts.
• The main benefits of composites over
metals technology have been
• Structural weight savings,
• Fatigue resistance and
• Corrosion suppression
It took only a few years for composite materials to prove
themselves suitable for use in commercial aircraft.
Commercial aircraft are currently under design and manufacture (e.g., Airbus
380 and Boeing 7E7) that will make extensive use of composite materials.
Up to 60% of the structure of the 7E7 will be composite materials.
Unmanned combat air
vehicle (UCAV)
Northrop Grumman’s X-47A
unmanned combat air vehicle
(UCAV) is composed mainly of
carbon fibre/epoxy matrix
composites with a room
temperature cure (i.e., no need for
autoclave).
Wingspan of 8.5 m, length of 8.5 m,
and empty weight of 1,743 kg.
Tailless, kite-shaped vehicle allows
improved low-speed handling.
Unmanned combat air vehicle (UCAV)
Boeing X-45 military unmanned combat
air vehicle (UCAV) with a planned
combat radius of approximately 2,000
km.

Fuselage consists of composite skins

(carbon fibre/epoxy matrix) in
addition to composite foam wings.
Upper skin is one piece of size 9 m x
3.7 m.

Higher temperature composite (carbon

fibre/bismaleimide) used close to
exhaust nozzle with maximum service
temperature of 204 ° C.
Aircraft fuselage

Portions of the fuselage for

the A380 will be produced
from glass-reinforced
aluminium laminate (known
as GLARE).
The resulting GLARE is
stronger than typical
aerospace materials (e.g.,
7075 aluminium) and a
fatigue life of 10~15 times
higher.
Civilian aircraft

The Airbus A380 currently

under manufacture will
make use of significant
amounts of composite
materials for the
fuselage, tail wing,
ailerons, and pressure
bulkhead.
Aerospace: Apollo spacecraft; Saturn
SII booster Launch Vehicle, Rocket
bodies.
Composites in Space
Applications
Space Shuttle Orbitor
Pioneer 10 Space craft
 Composites for Offshore
Applications
• Composite Piping System
• Composite Topside Applications
• Composite Grids/Gradings
• Composite Ladder & Handrail Components
• Flexible Thermosetting Tube
• Composite Pressure Risers
• High Pressure Accumulator Bottles
Composite in Automotive
applications
High performance cars

The use of carbon fibre/polymer

composites can result in weight
savings of 75~80% compared to
steel, 30~40% compared to
aluminium, and 50% compared
to chopped fibre glass
reinforced composite.

At least twenty five street legal

cars currently use carbon fibre
composites.
High performance cars

Ford produced a car

almost entirely from carbon
fibre composite as long
ago as 1979
in response to the high fuel
cost at that time.
Use of composite materials
reduced the weight by 544
kg
compared to the equivalent
steel version.
Fabrication of Composite Bus
Trimming
Skeleton of Composite Bus
Composite Bus
Automotive Applications
Automotive Applications
Semi structural Material
Formula 1 Car with Composites
Trailer unit

The Composite trailer is

produced almost entirely from
Fibre glass/vinyl ester composite
including the floor, sides, roof,
cargo doors, and chassis.
The unit weighs 25% less
compared to an equivalent
metal trailer and has superior
corrosion resistance.
This combination is expected to
result in significantly reduced
operating costs.
Fibreglass tanks and tubes
The direct cost of metallic corrosion
in the U.S. is estimated to be US$
276 billion each year.
This is equivalent to 3% of gross
domestic product (GDP).

Examples include highways,

bridges, pipelines, water and
sewage systems, ships and aircraft,
industrial plants, and military
installations.
Fibreglass tanks and tubes

Fibre glass-reinforced vinyl

ester composite tanks with a
8.5 m diameter and 13 m
length was selected for use in
a water treatment plant due its
excellent corrosion resistance.
Similar composite tubes have
been used as a 142 m high
chimney stack liner.
Cryogenic Fuel Tank
Reusable one-piece liquid
hydrogen fuel tanks for launch
vehicles (up to 8.5 m diameter and
24.4 m long).
Composite fuel tanks are 10~25%
lighter compared to aluminum
tanks, allowing larger payloads
and/or reduced launch costs.
Important to design composite
tank to minimize permeation of the
tank by hydrogen molecules.
Power poles and cross
arms
Composite power poles and cross
arms to be marketed by largest
North American maker of wooden
utility poles.
Poles are produced from pultruded
glass fibre-reinforced polymer
composites.
Service life of >80 years makes them
ideal for installation in remote areas.
Non-conductive, lightweight cross
arms produced from pultruded fibre
glass-reinforced polyester.
Pultrusion Process
Wind turbine blades

The use of composite materials

in wind turbine blades has
resulted in large advances in
blade size and resulting power
output.
Wind turbine blades tend to
use mainly glass fibre
composites with highly
stressed regions being
reinforced with carbon fibre
composites.
Wind turbine blades

The largest wind turbine blade

currently has a length of 61.5 m
and weight of 18,000 kg.
The blade will be used on a 5
MW turbine with a diameter of
125 m.
The use of composite materials
for the blade decreases the
demands on the hub
components and tower
structure, decreasing capital
and operating expenses.
Wind turbine blades

Dynamic testing is used to

simulate the 20 year lifespan
of the blade (5 million cycles).
The most important point for
wind turbine blades is to
reduce gravity-induced
bending loads, hence the use
of lightweight composite
materials.
Typical wind turbine blade
lengths are now up to 40 m.
Blade Type Rated Power

LM 29.1 P 1250 kW
LM 37.3P2 1500 kW
LM 34.0P3 2000 kW
LM 40.0 P 2000 kW
LM 40.3 P 1500 kW 
LM 45.3P 2000 kW
LM 38.8 P 2500 kW
LM 43.8 P 2300 kW
LM 48.8 P 3000 kW
LM 61.5 P 5000 kW
Construction
Composites in Civil Engineering
Strengthening of Columns
Strengthening of Bridge
Water Pressure Vessels - Velath
Pipe lines and Insulators- Velath
Water heaters – Velath
Luxury Boat – Velath, Chennai
Luxury Boat – Velath, Chennai
Boat interiors - Velath
Ceramic Matrix Composite
In particular carbon fibre reinforced
composites offer exceptional stiffness and
strength properties compared to common metals

TWICE the stiffness of aluminium

-FIVE times stronger than aluminium
-FIVE times lighter than steel
Application of C/C Composites
Application of C/C Composites
Industrial Application of CC
Application of MMC
Multifunctional Composite
Materials
 FUTURE MFCM AND MFS
DIRECTIONS

• Future spacecraft and aircraft will have

more stringent weight and volume
reductions.
• will require the incorporation of other
critical engineering functions.
• Energy generation and storage, propulsion,
attitude control, communications, etc
Medical applications

Artificial limbs – composite

prosthesis.
Composite Prosthesis
 Sports

Sports bike, Motor bike, Power

boat, sail boat, rifles etc.
Fig. A Flax reinforced
Catamaran Hull
Composite sports Bicycle
Carbon fiber reinforced epoxy
bicycle frame
 Music

Musical instruments – Guitar –

Clear
and resonant sound
Composite Stringed Instruments
 Domestic Purpose:

Furniture, roofing etc.

The applications of composites is
ever increasing.
Furniture made up of Composite
Resin Transfer Moulding
 RTM Applications
• Auto body panels • Propellers
• Truck air deflectors • Bathtub/shower
• Wind blades units
• Chemical storage • Antenna dishes
tanks • Chairs
• Solar collectors • Swim pool pane
(40 ft diameter,
36 parts)
Resin Infused Part
NATURAL FIBER
COMPOSITES
 Natural fibers
• Bamboo, Sisal
• Coir ,Banana
• Pineapple Leaf Fibre
• Jute, Tamarind Fruit
• Ridge Gourd Vegetable Fabric
• Napier Grass
• Flax
 Advantages

• Renewable
• Low Cost
• Eco Friendly
• Cellular Structure (Micro pores)
 Disadvantages of natural fiber
composites
• Lower Aspect ratio
• Lower thermal stability
• Non-Uniformity in dimensions
 Fiber Preparation
Fibres were treated with 5%
aq.NaOH solution for 1 hour to
remove dirt, greasy material,
hemicellulose etc., washed with
distilled water and dried in the Sun for
one week and finally dried in vacuum
oven at 110 ºC for 48 hours before use.
Some final remarks on natural
fiber composites
When the natural fibres and fabric was used
as reinforcements in the composites, the
tensile properties were enhanced several
times.
Narrow interface is observed between the
fibres and the matrix facilitating good stress
transfer.
The natural fibre reinforced polymer
composites are partially degradable as the
fibres are biodegradable.
NANO COMPOSITES
Nanomaterials and Some Current Products
• Fullerenes and Carbon Nanotubes: Fabrics, Cosmetics,
Electronics, Sports Equipment, Lubricants, Building
Materials, Food Supplements, Food Flavorings
• Silver: Antibacterials, Antifungals, Self-Cleaning Glass,
Spermicidal Condoms, Food Storage Containers, Air
Sanitizer
• Silica: Electronics, Paints/Pigments, Cosmetics, Food
Supplements
• Zinc Oxide and Titanium Oxide: Clear – thin film
sunscreens, Cosmetics, Self-Cleaning Coatings, Lens
Defoggers
• Gold: Chemical Detection, Home Pregnancy Tests,
Wrinkle
Nano Composite Applications