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Advanced Composites as High-End Engineered Materials
K.S.Krishnamurthy, PhD
Date : 05th March 2009

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Advanced Composites as High-End Engineered Materials

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he quest for using light-weight structural materials, which also have the necessary strengths, especially in aerospace industry led to the development of the modern fiber reinforced laminated composite materials in the late 70’s. While light weight metals such as aluminum or its alloys were widely used in the industry, they still lacked the necessary strengths and stiffnesses required in high strength applications. These limitations of pure materials or alloys were overcome by embedding fibers of glass, carbon, Boron and other substances in a metal or polymer matrix paving the way for an era of advanced man made materials of high strength. The fundamental idea of reinforcement of a weaker matrix material with tougher fibrous materials has, however, always existed since primitive times and is still being used in a variety of ways- in simple to complex engineering application domains. Mud mixed with jute or straw are still being used for building construction in certain societies, with an intuitive understating of the improvement in structural behavior. Reinforced cement concrete was invented with similar ideas, as hardened concrete though having a high compressive strength can resist negligible tensile loads. Mild steel bars with a good bond in the concrete matrix are designed to take all the tensile forces while concrete resisted compression. With this fundamental idea, the use of reinforced concrete became a huge success in the construction industry, which until then was facing the difficulty of supporting larger structural spans without resorting to the construction of arches.

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Advanced Composites as High-End Engineered Materials

In a similar manner, fiber reinforced composites are the choice of engineers for advanced applications, e.g., making the body of a spacecraft, for making the supporting frame work of an antenna in space, etc., where the desirable engineering properties (performance) rather than the cost of manufacturing the material is the prime consideration.

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Advanced Composites as High-End Engineered Materials

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ne of the key contributions that led to the development of fiber reinforced composites came from the understanding developed in the science of fracture mechanics besides the technology involved in making very thin fibers (of the order of microns), thermoplastics, and other manufacturing processes. It was understood that the mechanical properties of solids depended significantly on the nature and distribution of defects and anomalies present at a microscopic granular level, e.g., finely drawn fibers contained fewer defects and that was the reason for their high tensile strengths.

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Advanced Composites as High-End Engineered Materials

T

he advantage of composite materials is normally expressed through the stiffness/weight ratio achievable while comparing with an equivalent metallic structural component. Some of the well known everyday materials, e.g., like ‘Fiber glass’, are made of glass fiber reinforced plastics. Other well known fiber materials are carbon (graphite), Kevlar (made by Dupont), and Boron fibers. Graphite-epoxy composites, (also called carbon fiber composites), for instance, are very standard composites used widely. Kevlar fibers have very high strength and special composites are made with them, e.g., as aircraft parts, bullet proof vests, etc. Increasing use of the composites can be seen in infrastructure, sports goods (sail boats, bicycles, etc.), bio-medical(special implants), automotive, space, and innumerable other industries as well. Examples of composites’ use in aircraft industry

(source of phtographs: RM Jones’s book)

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Advanced Composites as High-End Engineered Materials

The concept of a lamina (fibers in a matrix material)

Building a laminate using laminas

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Advanced Composites as High-End Engineered Materials

Basic building material (lamina in tape roll form)

(sourced from the book by RM Jones) What is obvious in all these cases is the fact of using a light weight construction material which can produce desirable structural properties in the final product. Another admirable property of the high strength composite materials is the high degree of adaptability they can be put to in special situations. An example of such an application is the use of composites in structural retrofitting work to strengthen structural members of a building weakened due to an earthquake induced shaking. The fact that a composite material can be molded and cured to desired shapes has led to its use in the boat industry extensively where achieving accurate curvatures can be more cumbersome otherwise, although this alone was not the prime consideration for its enhanced usage. Similarly, filament winding technologies have been very successfully deployed in making pipes, tubes and other objects of revolution.

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Advanced Composites as High-End Engineered Materials

Rocket engine casing made in this manner is an example shown below (See Jones’ book)

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Advanced Composites as High-End Engineered Materials

Manufacturing process:
Composites are of various types, viz, those with randomly distributed fibers, and, secondly, laminates. An example of the former type is the case of a crash helmet. Generally randomly distributed fibered products are molded and cured. The process of making laminates on the other hand is more involved. Firstly, uni-directionally laid fibers embedded in the matrix material are manufactured in the form of tapes called pre-pegs (see figure). Any piece of a finite length cut from a such a tape is known as a lamina. To achieve uniform directional properties, laminas are laid over each other in different pre determined directions and fused together to form laminates (see figure). Thus structural materials of desired directional properties can be manufactured.

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Advanced Composites as High-End Engineered Materials

Structural forms, design and analysis
(Challenge for the Engineer) The basic structural components can generally be grouped into beams, plates and shells. Other shapes in the form of cylindrical or conical shapes are custom made. The challenge for the designer lies in the fact that unlike a conventional structural material like steel, fiber reinforced composites are orthotropic requiring the determination of nine basic elastic constants as against two required for a homogeneous isotropic material like steel or aluminum. The mechanical behavior of a laminated composite is complex and requires a good understanding of the concepts from the theory of anisotropic elasticity. Thus for an analyst grounded in the subjects of mechanics and engineering the analysis of composite behavior presents an excellent challenge and a fertile ground for carrying out research and development. However, the composite industry is now well developed, significantly big and mature. A large body of industry-related as well as academically oriented literature exists in the form of books, journals and other periodicals. Much information can be traced through the internet medium as well.

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Advanced Composites as High-End Engineered Materials

What we can do
With our excellent capabilities in CAE & CAD, especially in the areas of solid modeling, structural analysis, Engineering mechanics and Finite element analysis for stress-deformation studies of solids, and with the knowledge of micro and macro mechanics of laminated composites, we should be able offer consultancy services in the analysis of composites used in aerospace and other industries, e.g., in carrying out work such as: FE modeling & Analysis of laminated composite structural components for Stress-deformation analysis and design check of composite plates, shells, solids & structural shapes under static and dynamic loading Buckling Analysis Study of impact response Damage prediction etc We have all the necessary tools, e.g., CAD tools – Pro E, Catia, etc. FE tools – Ansys, Hypermesh, Nastran Structural – Staad Pro

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Advanced Composites as High-End Engineered Materials

Contact Us
At ITC Infotech, we offer to global customers the entire range of IT and IT enabled offshore outsourcing services. We will be happy to understand what you are looking for and provide customized solutions and services. Do get in touch with us at contact.us@itcinfotech.com

Locations
New Jersey ITC Infotech (USA) Inc. 12 Route 17 North Suite 303, Paramus New Jersey, USA 07652 Tel: +1.201.336 9431/32 Fax: +1.201.291 1370 Milton Keynes ITC Infotech Ltd, UK Norfolk House 118 Saxon Gate West Milton Keynes MK9 2DN, United Kingdom Tel: +44.1908.230 055 Fax: +44.1908.695 573 Bangalore ITC Infotech India Ltd. ITC Infotechpark Pulikeshinagar P .O. Bangalore - 560005 Tel: +91. 80.2298 8331 - 38 Fax: +91. 80.2298 8076

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