COMPOSITE MATERIALS

Dr. Adel M. Abd El-Mageed

Introduction
Composites are mixtures of two or more various materials, mixed in such a way that makes better
use of its constituent elements.
Composites have two main components: matrix and reinforcement. Polymer, metal, and ceramic
matrices are all continuous phases. When compared to metal matrix composites, polymers matrix
composites have lower stiffness and strength, while metal matrix composites have higher ductility and
high strength.
The aim of matrix material is to keep the embedded phase in place while sharing the load with the
secondary phase. The type of composite application determines which matrix to use.
Reinforcements or embedded phases, such as glass, carbon, organic, boron, ceramic, and metallic
fibers, are often stronger, stiffer, and harder than the matrix. As indicated in Fig. 1, composites are
characterized by the geometry of the reinforcement (particulate, flake, continuous and non-continues
fiber) or the type of matrix (polymer, metal, ceramic, and carbon).
Fig. 1. Composite material classification
Furthermore, composites can be categorized into the following categories based on reinforcement
geometry:
a) Dispersion: uniformly dispersed, ranging in size from 0.01µm to 0.1µm and in a volume
percentage ranging from 1 to 15% are used to enhance the strength and hardness of this type of
composite.
b) Particle: This is like dispersion-strengthened, except the particles are larger than 0.1µm and
volume percentages can exceed 15%.
c) Fiber: This category includes all sorts of continuous and non-continuous fibers, including the entire
range of reinforcing concentrations.
• The following parameters influence the properties of the composites:
- Constituent phase properties,
- Constituent relative quantities,
- Interfacial reactions between constituents,
- The dispersed phase's geometry,
- Particle shape,
- Particle size,
- Particle distribution.
Various properties of the composites evaluated (determine) by the rule of mixture, which maintains that
the property of the composite is the sum of products of the property of an individual element and its
volume fraction (v) in the composite. For example:
𝐷𝑒𝑛𝑠𝑖𝑡𝑦 (ρC) = ρr × vr + ρm × vm
where, ρ is the density and subscripts c, r, and m represent composite, reinforcement, and matrix
respectively. This theoretical computation can be performed to calculate the possible properties of the
prepared composite. As a first approximation, the rule of a mixture can be used to determine elastic

modulus, strength, and electrical characteristics.

Classification of Composites Based on Matrix Materials
Composites are categorized into three types depending on the nature of matrix material; polymer matrix
composites (PMCs), metal matrix composites (MMCs), and ceramic matrix composites (CMCs).
Depending on the geometry of the reinforcements, metal matrix composites are classed as fiber
reinforced, short fibers reinforced, or particles reinforced.

By combining the characteristics of matrix and reinforcement, the composite achieves the required
properties. When ceramic particles are added to a metal matrix material, the MMC,s can be used in
various applications. Due to the right selection of matrix material and reinforcement, parameters like
ductility, modulus of elasticity, strength, toughness, and hardness of the MMC,s can be enhanced or
change.
Metal Matrix Composites
Metal Matrix Composites (MMCs) have developed as a class of excellent engineering materials in the
modern industries such as, aerospace, defense, automotive, electronic, thermal and wear
applications outstanding to their advantages over the conventional monoliths (Fig. 2) . Because of its
high heat and electrical conductivity, copper has been widely employed as a matrix. Pure copper, on
the other hand, does not have the suitable mechanical properties.
 Red mud

Fig. 2 Different matrix and reinforcing materials used for the creation of MMCs
Reinforcement such as continuous or discontinuous fibers, wires, and particles can be used to
strengthen the matrix. Ceramic reinforcements, which might take the form of oxides, carbides, or
nitrides, are commonly used. Fine ceramic particles in copper, such as oxides or carbides, improve
strength and hardness while causes very minor electrical conductivity degradation.
The thermal and chemical stability of the reinforced particles, low diffusivity and low solubility in the
matrix, high interfacial energy, cohesion with the matrix, and reinforcement thermal coefficients of
expansion are the most important requirements for particle dispersion composites.
Metal Matrix Composites (MMCs) have a high strength-to-weight ratio and a high stiffness-per-density
ratio, which improves service performance. For example, Cu-Ni/Al2O3 composite material is used in a
variety of applications, including relay blades, railway overhead current collector systems, single-phase
induction machines, resistance welding electrodes, and electrical connectors.
Metal Matrix Composites Fabrication Methods
Metal matrix composite can be prepared by numbers of processing methods. The selection of proper
processing technique depends upon application area, quality, and distribution of reinforcement.
Different characteristics of the fabricated composite can be achieved by changing the production
processing and finishing method even when the same amount and composition of components are
the same. Metal matrix composites can be manufactured either by solid-state (ex-situ) and in-situ
processing.
Powder Metallurgy
There are several metals, metal oxides, and non-metallic materials in the powder form can be mixed
by the required volume fraction of the constituents by using the powder metallurgy method. At room
temperature, powder metallurgy is the only possible means of producing this type of combination
(composites).
Cold compaction follows the blending stage to generate the appropriate shape, which is roughly 80%
dense and simple to handle. Consolidation/sintering of green compact is an important stage in the
powder metallurgy approach for producing composites. Sintering is the process of heating and
consolidating powder at (sintering temperature, Ts ≤ 0.5 Tm (Tm is the absolut, melting temperature),
resulting in the formation of a dense body through mass transfer by diffusion.
Hot isostatic or uniaxial pressing is used to achieve a totally dense body. The flowchart of the powder
metallurgy route is shown in Fig. 3.

Fig. 3. Flow diagram of powder metallurgy procedure

Mechanical Mixing (Alloying)
The processing of powder particles in high-energy ball mills is often referred to by Mechanical Alloying
(MA). Mechanical mixing is the technique of milling together powder mixes (of various metals or
alloys/compounds). This technique involves a material transfer to create a homogenous mixture.
The actual process of mechanical mixing begins with the correct proportioning of powders and
inserting the powder mix into the mill together with the grinding medium. This mixture is then milled for
the desired time until it reaches a steady-state, at which point the composition of each
powder particle matches the proportion of components in the original powder mix.
Following that, the milled powder is consolidated into a bulk shape and heat-treated to get the desired
microstructure and characteristics.
Mechanical Stirring process
Stir melt, which is good for dispersing micron-sized particles, fails when nanoparticles are added to
the metal matrix. Fig. 4 illustrates the stirring of metal matrix composite containing ceramic particles.
Inserting the particles and homogeneously dispersing in the molten melt is difficult due to the
increase in surface area with the reduction in particle size. The free energy of the system rises as
interfacial energy rises, causing agglomerates to form in order to re-establish the stable state.

Fig. 4 Stirring process of composite matrix with ceramic particles

In-situ method
The in-situ technique uses chemical reactions between different components to create new
components during the production process. The reactions of the chemical components generate the
required mixture of matrix and reinforcement.

A small quantity of energy must be introduced to get the reaction started. These are mostly
exothermic reactions that happen on their own once the reaction triggered. However, while
generating in situ composite materials, it's vital to remember that the forming phase percentages by
volume might often be considerably different.
In this method, the reinforcing phase (powder) is the distributed phase in the matrix material phase
(powder). In comparison to the ex-situ method, the reinforcement phase in the matrix is
thermodynamically highly stable and homogenously distributed through the matrix. The reinforcing
phase of the in-situ method degrades very little at high temperatures.
The interfacial bonding between the matrix and dispersed phase is strong and the interface of matrix
reinforcement are clean. Fine reinforced particles are generated in the in-situ method, resulting in
homogeneous particle distribution and better mechanical properties. Because of these two factors,
this method has a wide range of industrial applications. By the in-situ method, many composites are
prepared using metal matrix materials (Cu, Ni, Ti, Al, Fe) and dispersant second phase particles
(borides, oxides, carbides, nitrides, and their mixture) due to their increased demand in the industry.
In-situ synthesis of Cu-Ni/Al2O3 nanocomposites
For fabrication of the Cu-Ni/Al2O3 nanocomposite powders by the thermo-chemical route, transient
components might be soluble powders of copper nitrate, nickel nitrate and aluminum nitrate. The Cu-
Ni/Al2O3 nanocomposite can be created with the in situ chemical processes as follows;

1- Obtaining a water solution in which Cu(NO3)2.3H2O, Ni(NO3)2.6H2O and Al(NO3)3.9H2O are

dissolved by stirring the mixture with a magnetic and, 2- heating the stirrer at 70 °C for 30 minutes,
as shown in Fig. 5, up to achieving the required composition of Cu-Ni/Al2O3 nanocomposite.
3- Dry spraying involves using a sprayer at a temperature of 180 °C to get nitrate salt powder particles.

Fig. 5. Layout of preparing and mixing solution process

4- The nanocomposite powders of copper oxide (CuO), nickel oxide (NiO), and Al2O3 phases were
then made after oxidation heat treatment at 850 °C for 1 hour in an air environment, as shown in Fig.
6, according to the following equation:

Fig. 6. Layout of dry spraying and oxidation heat-treatment process

5- Reduction of thermally treated powders in hydrogen flux flow (0.1 L/min) at a temperature of 500 °C
for 30 min, as shown in Fig. 7. Then, the reactor was cooled under a high-purity argon atmosphere (at
the same flux) to minimize oxidation, whereas the copper oxide and nickel oxide were reduced to their
metallic state (Cu and Ni), while the Al2O3 remained as the dispersed ceramic phase, according to the
following equation:

Fig. 7 Layout of reduction thermally treated

powders in hydrogen process.
 The Cu-Ni/Al2O3 nanocomposite was created with the in situ chemical processes that have been
completed, as shown in Fig. 8.

Fig. 8. Illustration of synthesis procedures of Cu-Ni/Al2O3 nanocomposite using in-situ chemical process.
Ceramic Matrix Composites (CMCs)

Ceramic primary phase imbedded with a secondary phase, usually consisting of fibers.

▪ Attractive properties of ceramics: high stiffness, hardness, hot hardness, and compressive strength;
and relatively low density.
▪ Weaknesses of ceramics: low toughness, l0ow tensile strength and the susceptibility to thermal
cracking.
CMCs represent an attempt to retain (keep the desirable properties of ceramics and compensating
(achieving) for their weaknesses.

Polymer Matrix Composites (PMCs)

Polymer primary phase in which a secondary phase is imbedded as fibers, particles, or flakes.
Commercially, PMCs are more common than MMCs or CMCs. Examples: most plastic molding
compounds, rubber reinforced with carbon black, and fiber-reinforced polymers (FRPs).
Polymer matrix materials:
Usually a thermosetting plastic such as unsaturated polyester or epoxy. Can also be thermoplastic,
such as nylons (polyamides), polycarbonate, polystyrene, and poly-vinylchloride. Fiber reinforcement is
widely used in rubber products such as tires and conveyor belts.

Fibers Forms in Polymers Matrix Composites

Various forms, discontinuous, continuous, or woven. Common fiber materials in FRPs are fiber glass
and fiber carbon. Less common fibers include boron, SiC, Al2O3 and steel. Glass is the most common
fiber material in today's FRPCs. Its use to reinforce plastics from around 1920.
Common FRP Structure
Most widely used form of FRP is a laminar structure. Made by stacking and bonding thin layers of fiber
and polymer until desired thickness is obtained. By varying fiber orientation among layers, a specified
level of anisotropy in properties can be achieved in the laminate. Applications, boat hulls, aircraft wing
and fuselage sections, automobile and truck body panels.
FRP Properties
High strength-to-weight ratio and high modulus-to-weight ratios. A typical FRP weighs only about 20 %
of steel; yet, strength and modulus are comparable in fiber direction. Good fatigue strength and good
corrosion resistance. Low thermal expansion for many FRPs and significant anisotropy in properties.

FRP Applications
Aerospace – much of the structural weight of today’s airplanes and helicopters consist of advanced
FRPs (Example: Boeing 787 (Figure 9).
Automotive – some body panels for cars and truck cabs.
Sports and recreation.

.
FRPs used for boat hulls since 1940s. Fishing rods, tennis rackets, golf club shafts, helmets.

Figure 9 Composite materials in the Boeing 757

Figure 9 Composite materials in the Boeing 757