Unit 6

Manufacturing of Composites
Syllabus
 Introduction to composites, Composite properties,
Matrices, Fiber reinforcement
 Composite Manufacturing Processes: Hand lay-up
Process, Spray lay-up, Filament winding process,
Resin transfer moulding, Pultrusion, and
Compression moulding process, Vacuum
impregnation process, Processing of metal matrix
composites, Fabrication of ceramic matrix
composites, Carbon-carbon composites, Polymer
matrix and Nano-composites.
 Introduction to Composites
We need materials with special properties like
high strength & low density.
Composites are multiphase materials which can be
artificially made to get desired properties.
Composite materials are combination of two or
more individual materials with different physical
or chemical properties.
 Introduction to Composites
A Composite material consists of two phases: a
primary phase & a secondary phase.
Primary phase forms the matrix within which
secondary phase is embedded.
The embedded phase is referred to as reinforcing
agent, because it serves to strengthen the
composite.
The reinforcing phase may be in the form of fibers,
particles, etc.
Introduction to Composites
Introduction to Composites
 Introduction to Composites
The matrix is basically a homogeneous and
monolithic material in which a fiber system of a
composite is embedded.
It is completely continuous. The matrix provides a
medium for binding and holding reinforcements
together into a solid.
Matrix material can be polymers, metals or
ceramics which give shape to composite,
maintains fiber alignment & protects them against
environment & possible damage.
 Introduction to Composites
A reinforcement is a stronger material distributed
within the matrix.
Reinforcement gives strength, stiffness & other
mechanical properties to composite matrix.
Matrix & reinforcements are chemically bonded or
mechanically locked together.
Reinforcements like fibers, particles, flakes, fillers,
etc. are the main load carrying elements &
provides strength & rigidity to the composites.
Importance of Composites
 Properties of Composites

Around 25% reduction in weight

Tensile strength is 5-6 times higher
Improved stiffness & impact strength
High fatigue endurance limit
For same functional requirements, composites are
30-45% lighter than Aluminium structures.
Low vibration transmission
Excellent corrosion resistance & fire resistant
Composites are more versatile
Properties of Composites
 Applications of Composites
Composite materials find applications in following
industries:
Aerospace – Glass, carbon & Kevlar fiber
composites
Automotive – body panels
Construction – bridge structures, ceramic coating
Marine – power boats
Sporting equipment – Tennis rackets, golf shafts.
Consumer products – sewing machines, printers
Appliances, etc.
Classification of Composites
Classification of Composites
 Classification of polymers –based on Matrices
a) Polymer Matrix Composite (PMC)
It consists of a polymer resin [thermoset or
thermoplastic] as the matrix and fibers as the
reinforcement medium.
Polymers used are – Epoxy, PVC, Nylon, Polystyrene.
These are further classified based on type of fibers
used as –
1. Carbon fiber reinforced polymer (CFRP) – These have
high strength & high stiffness to weight ratio.
2. Glass fiber reinforced polymer (GFRP)
Matrices are mostly cross-linked thermoset polymers.
These are used in automotive & marine industry,
plastic pipes, industrial floorings, containers, etc.
 Classification of polymers –based on Matrices
b) Metal Matrix Composite (MMC)
It consists of a metal or an alloy (Al, Mg, Fe, Co, Cu) as
continuous matrix and particles, short fibers, whiskers as
reinforcement.
MMCs are used to increase mechanical properties like yield
strength, tensile strength, etc.
These composites have greater operating temperatures &
higher resistance to degradation.
MMCs are light metals like Al, Ti & Mg.
Aluminium is most commonly used due to its excellent
strength, toughness & resistance to corrosion.
MMCs are used in drive shafts rotating at higher speeds &
minimize vibrational noise levels & in forged transmission
parts.
A metal matrix composite which uses a continuous fibre SiC reinforcement
coupled with a Ti-5Al-5Mo-5V-3Cr (Ti-5-5-5-3) matrix is presented.
 Classification of polymers –based on Matrices
c) Ceramic Matrix Composite (CMC)
It consists of a ceramic matrix & embedded fibers of
other ceramic materials.
These are used to produce materials which resist
failure due to fracture.
They are resilient to high temperatures & oxidation,
hence, suitable for high temperature & high stress
applications such as parts in automobiles & aircraft gas
turbines engines.
Silicon carbides is used for both matrices &
reinforcements.
Processing of Composites
 Processing of Composites
Open Moulding: -
Raw materials like resins & fiber reinforcements are
exposed to air when they cure or harden.
These include –
1. Hand lay-up
2. Spray-up
3. Filament winding
Advantages of open moulding –
1. Low cost due to less tooling
2. Suitable for prototype development
3. Useful for low volume production.
 Processing of Composites
Closed Moulding: -
Raw materials like resins & fiber reinforcements are cured
inside a two-sided mould or within a vacuum bag.
These include –
1. Vacuum bag moulding
2. Vacuum infusion processing
3. Resin transfer moulding
4. Compression moulding
5. Pultrusion
Advantages of closed moulding –
1. Allows for more complex part geometries
2. Production is faster & more consistent
3. Useful for High volume production
4. Less waste is produced.
Hand lay-up moulding
 Hand lay-up moulding
It is the most commonly used and less expensive
method of open moulding.
Fiber reinforcements are placed by hand in a mould &
resin is applied with a brush or a roller.
It is used to make both large & small products including
storage tanks, tubs & showers, etc.
Gel coating is first applied to the mould, once gel coat
gets cured, fiberglass reinforcement is manually placed
on the mould.
Subsequent layers of fiberglass reinforcement are
added to build laminate thickness.
Low tooling cost, good production rates & simple
processing.
Spray-up moulding
 Spray-up moulding
Spray-up is an open-moulding composites fabrication
process where resin and reinforcements are sprayed
onto a reusable mould.
Fibre is chopped in a hand-held gun and fed into a
spray of catalysed resin directed at the mould.
The deposited materials are left to cure under standard
atmospheric conditions.
Applications: Simple enclosures, lightly loaded
structural panels, e.g. caravan bodies, bathtubs.
Low cost way of quickly depositing fibre and resin.
Low tooling cost, good production rates & simple
processing.
Filament winding
 Filament winding
Filament winding is the process of winding fiber material &
resin around a shape, known as mandrel, to create
composite product.
It is typically used to create circular composite products
with a hollow core.
Fibre tows are passed through a resin bath before being
wound onto a mandrel in a variety of orientations,
controlled by the fibre feeding mechanism, and rate of
rotation of the mandrel.
It gives high tensile strength to the hollow components like
chemical & fuel storage tanks, pipes, pressure vessels, etc.
The filament is laid down in a pre-defined geometric
pattern to provide maximum strength.
When required layers have been applied, laminate is then
cured on mandrel with heating element.
Vacuum bag moulding
 Vacuum bag moulding
In this process, layers of fibers, impregnated with
uncured resin, are laid on top of a mould,
layer‐by‐layer. Once the layup is complete, the overall
fiber stack up is covered with a flexible bag.
It utilizes a flexible film to enclose the part and seal it
from the outside air.
By evacuating the air between the mould and the
vacuum bag using a vacuum pump, the part is
consolidated under atmospheric pressure.
Once curing is complete, constituent materials become
one integrated mass in desired shape.
Vacuum infusion moulding
 Vacuum infusion moulding
Vacuum infusion process differs from vacuum bag
process in which the resin is infused or inserted with
the resin pump into the mould after vacuum has pulled
the bag down & coated the laminate.
Vacuum infusion enables very high resin-to-glass ratios
and the mechanical properties of the laminates are
superior.
Vacuum infusion produces laminate with same level of
integration, producing high strength and low weight
structures.
Resin transfer moulding
 Resin transfer moulding
Resin Transfer Moulding, commonly known as RTM, is
a wet process, where fibers and resin are placed in the
mould separately.
First, layers of fibers are placed in the mould
layer‐by‐layer. Once all the layers of fibers have been
placed, pressurized resin is introduced in the mould to
impregnate the fibers. The mould cavity, into which
resin flows, has inlets for resin, and also vents for air.
Once the mould is full of resin, the system is heated to
initiate curing.
Compression moulding
 Compression Moulding
Compression moulding is a closed-mould composite
manufacturing process that uses matched metal
moulds with the application of external pressure. The
combination of heat and pressure produces a
composite part with low void content.
A typical compression moulding process is performed
at a mould temperature of 350°F and mould pressure
of 100 psi (180°C and 700 kPa) with curing time of 3
min.
After the material is cured, the mould is opened and
the plastic package is pushed out.
Compression moulding is a low cost process and is
capable of high volume production.
Compression moulding
Pultrusion
 Pultrusion = Pulling + Extrusion
Pultrusion process is a highly automated continuous
fibre laminating process producing high fibre volume
profiles with a constant cross section.
It is used for manufacturing of products such as rod
stocks, beams, channels, pipe, tubing, fishing rods, etc.
The continuous glass fiber is filled in a resin bath &
then it is pulled through a steel die.
The die is heated to rapidly cure the resin.
It produces profiles with high fiber loading, hence,
parts produced have high structural properties.
Pultrusion
Processing of Metal Matrix Composites
 Solid State Processing
1. Powder blending & consolidation:
Metal alloy powder is blended with short fibers or
particles in dry condition.
After blending, mixture is further processed by cold
compaction & high temperature consolidation.
This method is used for processing of Aluminium &
Magnesium metal matrix composites.

2. Diffusion Bonding:

It is a solid-state joining process applicable to similar &
dissimilar materials.
The inter-diffusion at metallic surfaces under pressure
creates bonding between metal matrix & fibres.
 Solid State Processing
3. Physical Vapour Deposition:
Fibers are continuously passed through a region of high
pressure of metal to be deposited.
Vapour is produced & inserted in the process, then the
condensation occurs at this region to produce a coating
on the fiber.
Coated fibers are then consolidated by hot pressing.
 Liquid State Processing
1. Stir casting:
Reinforcements are mixed with the liquid metal melt &
mixture then solidifies.
Pre-treated particles are inserted into the molten alloy
vortex.
Limitation of this method is that reinforcements are not
uniformly distributed & form sediments in molten alloy.

2. Squeeze casting:

The molten metal is poured into an open die. The dies are
then closed so that molten metal solidifies under pressure
within the dies.
The heat is transferred from molten metal to dies under
high pressure. As a result, a fine grain casting is produced.
 Liquid State Processing
3. Infiltration:
The liquid metal alloy is infiltrated into the porous
fibers or whisker reinforcements.
Silica & metal-based mixtures are commonly used as a
binder to retain shape of porous forms.

4. Spray deposition:

The particles or whiskers or short fiber reinforcements
are injected in the form of spray, creating a deposition
layer on metal surface.
The depositions are then consolidated to full density by
further processing.
Processing of Ceramic Matrix Composites
• 1. Chemical Vapour Infiltration (CVI)
• 2. Liquid Phase Infiltration (LPI)
• 3. Polymer Infiltration & Pyrolysis (PIP)
• 4. Sol-Gel Infiltration (SGI)
Chemical Vapour Infiltration (CVI)
Chemical Vapour Infiltration (CVI)
In this method, the reactant gases diffuse into an
isothermal porous preform made of long continuous
fibers & form a deposition.
The deposited material is a result of chemical reaction
occurring on the fibers surface.
The deposition fills the space between fibers, forming
composite material in which matrix is the deposited
material & dispersed phase is the fibers of the preform.
Method is used for fabrication of silicon carbide matrix
composites reinforced by silicon carbide long
continuous fibers.
 Chemical Vapour Infiltration (CVI)
Advantages
Low residual stresses
Higher mechanical properties
Thermal & shock resistance is good
Matrices of various compositions may be fabricated.
Limitations
Very slow processing rates
Higher capital & production costs.
Liquid phase infiltration
 Liquid phase infiltration
It utilizes infiltration of a liquid into long continuous
fibers.
Infiltration of molten ceramic into a fiber preform is
limited by low viscosity of molten ceramics and by high
temperature causing chemical interaction between the
molten matrix and the dispersed phase (fibers).
The process involves infiltration of carbon (C)
containing preform with molten silicon (Si).
Infiltration is usually capillary forced.
Carbon of the impregnated preform reacts with liquid
silicon, forming silicon carbide (SiC).
 Liquid phase infiltration
Advantages
Low cost
Production time is less
High thermal & electrical conductivity
Complex shapes may be fabricated
Limitations
High temperature of molten silicon may damage fibers
Residual silicon is present in carbide matrix
Lower Mechanical properties
Polymer Infiltration and Pyrolysis (PIP)
 Polymer Infiltration and Pyrolysis (PIP)
It consists of an infiltration of a low viscosity polymer
into reinforcing ceramic structure followed by
pyrolysis.
Pyrolysis is a process of chemically decomposing
organic materials at elevated temperatures in absence
of oxygen.
Due to pyrolysis, polymer decomposes & converts into
a ceramic.
The ceramics produced from pyrolysis are called as
polymer derived ceramics.
 Polymer Infiltration and Pyrolysis (PIP)
It involves the following operations:
Fiber preform (or powder compact) is soaked with a
soft (heated) polymer, forming polymeric precursor.
The polymer is cured (cross-linked) at 480 ºF ( 250 ºC).
The polymer precursor is then pyrolyzed at 1472-
2372°F (800-1300°C). As a result of pyrolysis the
polymer converts to ceramic. Pyrolysis causes
shrinkage of the matrix material and formation of
pores (up to 40 vol.%).
The pyrolyzed polymeric cursor may be hot pressed for
densification.
 Polymer Infiltration and Pyrolysis (PIP)
Advantages
Good control of the matrix composition &
microstructure
Different types of reinforcements can be used
Minimum damage to the fibers
Disadvantages
Processing time is relatively long due to multiple
infiltration – pyrolysis cycles.
Residual porosity reduces mechanical properties of
composites.
Production cost is high.
 Sol-Gel Infiltration (SGI)
This process involves preparation of matrix from a liquid
colloidal suspension of fine ceramic particles called Sol,
which soaks a preform & then transforms to solid called as
gel.
Colloidal suspension is formed as a result of chemical
reaction when very small particles with radii up to 100 nm
(nanoparticles) precipitate within a liquid (water or organic
solvent).
Liquid sols have a low viscosity therefore they easily
infiltrate into the preform.
At elevated temperatures sols undergo cross-linking
(polymerization).
Polymerization converts sol into gel – a polymer structure
containing liquid. Gels may be transformed into Ceramics at
relatively low temperature, which reduces the probability
of the reinforcing fiber damage.
Sol-Gel Infiltration (SGI)
 Sol-Gel Infiltration (SGI)
• Advantages of Sol-Gel Infiltration:

• Less reinforcing fiber damage due to low processing temperature;

• Controllable matrix composition;
• Low equipment cost;
• Low machining cost due to near-net-shape fabrication;
• Large and complex parts may be fabricated.

• Disadvantages of Sol-Gel Infiltration:

• Possible matrix cracking because of large shrinkage;
• Multiple infiltration-gelation cycles are required in order to
increase the ceramic yield;
• Low mechanical properties;
• High cost of sols.
Carbon-carbon composites
 Carbon-carbon composites
 These composite materials have high tensile strengths,
creep resistance, high fracture toughness & these
properties are retained upto 2000 ̊C.
 Two methods are used to fabricate carbon – carbon
composites:
 1. Liquid phase infiltration process
 2. Chemical Vapour deposition
 Carbon-carbon composites
Advantages
High strength & high modulus of elasticity
Excellent thermal shock resistance
Low coefficient of thermal expansion
High thermal & electrical conductivity
Low density & high abrasion resistance
Disadvantages
Low oxidation resistance
These composites are expensive
Applications
Rocket motors, aircrafts, advance turbines
Hot pressing moulds
Brake discs for high speed aircrafts
 Nano composites
 Nano composites are materials that incorporate Nano
sized particles into a matrix of standard material.
 The result of the addition of nanoparticles is a drastic
improvement in properties that can include mechanical
strength, toughness and electrical or thermal
conductivity.
 The effectiveness of the nanoparticles is such that the
amount of material added is normally only between
0.5 and 5% by weight.
 Nano composites
• Improved Properties
• Nano composites can dramatically improve
properties like:
• Mechanical properties including strength,
modulus and dimensional stability;
• Electrical conductivity;
• Flame retardancy;
• Thermal stability;
• Chemical resistance;
• Surface appearance.
Classification of Nano composites
 Nano composites
• How Nano composites Work
• Nanoparticles have an extremely high surface to volume
ratio which dramatically changes their properties when
compared with their bulk sized equivalents. It also
changes the way in which the nanoparticles bond with the
bulk material.

• Applications:
• Thin-film capacitors for computer chips;
• Solid polymer electrolytes for batteries;
• Automotive engine parts and fuel tanks;
• Impellers and blades;
• Oxygen and gas barriers;
• Food packaging.