Applications of Composite
Applications of Composite
Applications of Composite
Introduction (1)
There are many reasons for the growth in composite applications, but the primary impetus is that
the products fabricated by composites are stronger and lighter. Today, it is difficult to find any
industry that does not utilize the benefits of composite materials. In the past three to four decades,
there have been substantial changes in technology and its requirement. This changing
environment created many new needs and opportunities, which are only possible with the
advances in new materials and their associated manufacturing technology. In the past decade,
several advanced manufacturing technology and material systems have been developed to meet
the requirements of the various market segments. Broadly speaking, the composites market can be
divided into the following industry categories:
1. aerospace,
2. automotive,
3. construction,
4. marine,
5. corrosion resistant equipment,
6. consumer products, appliance/business equipment, and
7. others.
The range of materials can be classified into the categories: (2) Metals, Polymers, Ceramics and
inorganic glasses and Composites.
Metals lose their strength at elevated temperatures. High-Polymeric materials in general can
withstand still lower temperatures. Ceramics outstrip metals and polymers in their favorable
melting points, ability to withstand high temperatures, strength and thermal expansion properties,
but due to their brittleness they are often unsatisfactory as structural materials. This lead to the
exploration of composites.
Emergence of strong and stiff reinforcements like carbon fibre along with advances in polymer
research to produce high performance resins as matrix materials have helped meet the challenges
posed by the complex designs of modern aircraft. The large scale use of advanced composites in
current programmes of development of military fighter aircraft, small and big civil transport
aircraft, helicopters, satellites, launch vehicles and missiles all around the world is perhaps the
most glowing example of the utilization of potential of such composite materials.
The Aerospace Industry (1)
The aerospace industry was among the first to realize the benefits of composite materials.
Airplanes, rockets, and missiles all fly higher, faster, and farther with the help of composites.
Glass, carbon, and Kevlar fiber composites have been routinely designed and manufactured for
aerospace parts. The aerospace industry primarily uses carbon fiber composites because of their
http://www.compositesworld.com/articles/the-outlook-for-thermoplastics-in-aerospace-
composites-2014-2023
The aerospace structures and features
Important requirements of an aerospace structure and their effect on the design of the structure
are presented in the below table.
APPLICATIONS (3)
Business and Commercial aircrafts
(1) The major reasons for the use of composite materials in spacecraft applications include weight
savings as well as dimensional stability. In low Earth orbit (LEO), where temperature variation is
from –100 to +100°C, it is important to maintain dimensional stability in support structures as well
as in reflecting members. Carbon epoxy composite laminates can be designed to give a zero
coefficient of thermal expansion. Typical space structures are tubular truss structures, facesheets
for the payload baydoor, antenna reflectors, etc. In space shuttle composite materials provide
weight savings of 2688 lb per vehicle.
Passenger aircrafts such as the Boeing 747 and 767 use composite parts to lower the weight,
increase the payload, and increase the fuel efficiency. The components made out of composites for
such aircrafts are shown in Table 1.3.
6. Submarine firs
7. Landing craft reconnaissance (15.8 meter)
8. Submarine non pressure hull casing
Increasingly, naval patrol boats are being built with an all-composite design or a composite hull
fitted with an aluminum super structure. The growing popularity of FRP patrol boat is due mainly
to their excellent corrosion resistance, which reduces maintenance costs, and lightweight. This can
result in better speed and fuel economy. It is estimated that the composite patrol boats are usually
approximately 10% lighter than an aluminum boat and over 35% lighter than a steel boat of the
same size. Carbon fiber composites are rarely used on naval vessels because of their high cost.
LEISURE, SPORTING AND COMMERCIAL FRP COMPOSITE CRAFT:
The composite material most commonly used in leisure and commercial craft is GRP in the form of
a thick laminate or a sandwich composite. Over 95% of all composite marine craft are built with
GRP because of low cost. There is however a number of other reasons for the popularity of GRP
composite in marine craft, and these include –
1. Ability to easily and inexpensively mould GRP to the near net shape, even for marine structure
with complex shape, such as boat hulls thus making it suitable for mass production.
Excellent corrosion resistance
3. Light weight, resulting in reduced fuel consumption.
4. Simple to repair
5. Ability to absorb noise and dampen vibrations, which makes for a more comfortable ride on
motor powered boats.
FABRICATION METHODS
Advanced fabrication processes, such as resin transfer, resin film intrusion, or auto craving are
used in the construction of hull and decks to produce composites that are defect free, excellent
dimensional balance and high fiber content for maximum stiffness, strength and fatigue resistance.
OFFSHORE APPLICATION OF FRP COMPOSITES:
The greatest problem with using steel in an offshore structure is the poor corrosion resistance
against seawater and other highly corrosive agents, such as hydrogen chloride. It is estimated that
the oil industry spends several billion dollars each year in maintaining, repairing and replacing
corroded steel structures. Composites offer the potential to reduce these costs because of their
outstanding corrosion resistance against most types of chemicals. It is estimated that composites
provide a weight saving of 30 to 50% compared to steel for many nonstructural components. The
most common types of composites used are GRP and phenolic composites, with the latter being
used because of good fire resistance. Advanced composites containing carbon fiber, kelvar fibers,
or epoxy resins are used sparingly because of their high cost.
disassembly of temporary structures much easier and less time-consuming than similar structures
made of wood or steel. Cost of many of the FRP composites, although higher than conventional
construction materials on a pound-per-pound basis, are competitive when the specific strength of
the materials is taken into consideration.
Vibration damping. The specific modulus of FRP composites, defined as the modulus of elasticity
divided by the density, is also high and provides characteristics such as low vibration in situations
where vibration may be a problem (Grace, Bagchi, and Kennedy 1991). Steel has a high density,
high modulus, and low damping characteristics whereas composites have low densities, moderate
moduli, and high damping characteristics. Use of composites in floors and bearing pads where
damping of vibration is of concern can reduce these problems.
Repair using composites. Structural repairs of conventional materials using FRP composites can be
advantageous from the standpoint of ease of installation and reduced maintenance costs.
Conventional techniques for externally strengthening cracked concrete structures call for steel
plates or bars to be installed across the crack to carry the structural loads no longer carried by the
concrete. FRP plates can be structurally bonded across such cracks to replace the steel repair
components. The low mass of these materials makes their handling more convenient, and their
noncorrosive natwe eliminates the need to protect them from rusting deterioration.
Corrosion resistance. One of the most convincing reasons to consider the use of FRP composites is
their resistance to corrosive elements. The plastic resins that form the matrix of most composites
are resistant to deterioration from many chemicals as well as the effects of acidic, salt, and fresh
waters. Acidic, salt, and fresh waters are corrosive to ferrous metals. The benefits of composites
over steel in terms of resistance to corrosion are greatest in the areas of maintenanc and life-cycle
costs. Components in marine construction such as piling, docks, and submerged construction
would be applicable uses. Storage structures for corrosive liquids are suited to FRP composite
materials. Fiberglass tanks have been used for storage of chemicals for many years.
Production Options
a. Fabrication. The variety of fabrication techniques that are available with FRP’s provide for many
custom properties. Multiple types of fibers can be combined to produce materials with the
advantages of each component; fibers can be oriented in specified directions to better suit
specialized loading conditions; and material properties such as strength and stiffness can be
controlled to meet the user need. Special molding techniques allow complicated pieces to be
fabricated as one unit, eliminating joint conditions which can be a source of weakness. One
method of producing FRP composites is by a technique known as pultrusion, other processes that
are commonly used include filament winding, autoclave molding, and scrimp, capabilities of these
materials is demonstrated in custom fabricated sandwich panels. In these panels, load bearing,
FRP, honeycomb core structures are sandwiched between FRP skin plates producing a very
strong, lightweight structural component.
b. Custom geometry. The length and geometry of a given pultruded cross section can be custom
designed as well. The pultrusion process lends itself to custom fabrications. The length of the
fabricated shape does not have to be a predetermined length. The designer can work with the
fabricator to produce products in lengths and shapes needed for specific applications.
c. Color and coating. Since the matrix of FRP composites consists of resins that begin in the liquid
state, many amhitectural treatments can be added before they harden. For example, custom
coloring can be added to the resins in the manufacturing process, thereby eliminating the need for
and cost of painting or other color application after the fact. Since the color is integrally mixed in
the matrix, it cannot be scraped off or abraded during its lifetime. It is also possible to embed sand
or other nonslip surface treatments as a secondary operation, and the treatment will become part
of the component. Nonslip gratings and walkways are an example of this type of application.
STRUCTURAL APPLICATION OF FRP MATERIALS (9)
Advantages
• Lightness
• Quick installation
• High durability
• Low maintenance
Rehabilitation
FRP SANDWICH PANELS – CONSTITUTION
FRP outer skins - thin, stiff, resistant
• Core - thick, light, more flexible, less resistant (rigid foam, balsa wood, etc.)
• Adhesive
There are many different kinds of sports equipment, the following are common fiber reinforced
composite material sports equipment to make a simple list (see table 1), and makes detailed
introduction of some products.
Table 1Examples of fiber-reinforced composite materials application in the sports equipment
Form Application
Plate-like structure Skis, surfboards, windsurfing, table
tennis boards, slats and gliding wing
spar etc.
Tubular structures Tennis, badminton, fishing rods, golf
clubs, baseball bats, hockey sticks, pole
shaft, etc.
Sheet structure All kinds of helmets, golf club heads, the
hull structure of the various boat classes
Other structures Match with a variety of vehicles, Sword,
climbing ropes, various lines etc.
Skis
Type of Composite
1. Wet Layup Glass and Carbon Epoxy
a. Di functional epoxy with amine curing agent
b. Woven, non woven, stitched uni and braided glass and carbon
c. Process: Wet Layup Compression Molding
Design Drivers
a. Stiffness and geometry driven
b. Manufacturing driven
c. Cost driven
d. Failures typically driven by:
i. Bond Failures
ii. Imperfections in structure
Material Selection Drivers
Cost
Bonding- Must join many dissimilar materials
Snowboards
Type of Composite
1. Wet Lay up Glass and Carbon Epoxy
a. Di functional epoxy with amine curing agent
a. Woven, non woven, stitched uni and braided glass and carbon
b. Process: Wet La yup compression molding
Design Drivers
a. Stiffness and geometry driven
b. Manufacturing driven
c. Cost driven
d. Some weight considerations
e. Failures typically driven by:
a. Core Failures
b. Imperfections in structure
c. Bond Failures
Material Selection Drivers
a. Cost
b. Weight
c. Bonding - Must join many dissimilar materials
Snowboard Bindings
Type of Composite
1. Injection molded glass nylon
Design Drivers
a. Shape complex
b. Strength
c. Weight
d. Cost
Material Selection Drivers
a. Strength
b. Low temp. high rate loadings
c. Complex shapes
d. Cost
Golf Club
A golf club is used to strike the ball in the game of golf. It has a long shaft with a grip on one end
and a weighted head on the other end. The head is affixed sideways at a sharp angle to the shaft,
and the striking face of the head is inclined to give the ball a certain amount of upward trajectory.
The rules of golf allow a player to carry up to 14 different clubs, and each one is designed for a
specific situation during the game.
Raw Materials
Golf clubs are manufactured from a wide variety of materials, including metals, plastics, ceramics,
composites, wood, and others. Different materials are chosen for different parts of the club based
on their mechanical properties, such as strength, elasticity, formability, impact resistance, friction,
damping, density, and others.
Club heads for drivers and other woods may be made from stainless steel, titanium,
or graphite fiber-reinforced epoxy.
Face inserts may be made from zirconia ceramic or a titanium metal matrix ceramic composite.
Oversize metal woods are usually filled with synthetic polymer foam.
Club shafts may be made from chrome-plated steel, stainless steel, aluminum, carbon or graphite
fiber-reinforced epoxy, boron fiber-reinforced epoxy, or titanium.
Grips are usually made from molded synthetic rubber or wrapped leather.
References:
1. Sanjay K. Mazumdar “Composites Manufacturing, Materials, Product and Process
Engineering”, CRC press, 2002.
2. Nikhil V Nayak, “Composite Materials in Aerospace Applications”, International Journal
of Scientific and Research Publications, Volume 4, Issue 9, September 2014.
3. http://www.oceanica.ufrj.br/ocean/cursosead/materiaiscompositos/compositematerials
/f_aerospace_applications.pdf
4. P, Beardmore, C.F. Johnson, and G.G. Strosberg, Ford Motor Co., entitled “Impact of New
Materials on Basic Manufacturing Industries—Case Study: Composite Automobile
Structure” 1987.
5. Composite Components for Automotive Engineering - Benteler SGL Composite
Technology GmbH
6. S.Ilaiyavel, "Applications of composites in marine industry", Journal of Engineering
Research and Studies, June,2011.
7. M. F. Humphreys, Queensland University Of Technology, Australia
8. Engineering and Design COMPOSITE MATERIALS FOR CIVIL ENGINEERING
STRUCTURES, DEPARTMENT OF THE ARMY U.S. Army Corps of Engineers
Washington, DC.
9. John P. Busel, Director, Composites Growth Initiative American Composites
Manufacturers Association "FIBER REINFORCED POLYMER (FRP) COMPOSITES
REBAR", July 17, 2012.
10. Lei zhang, " The application of composite fiber materials in sports equipment" Wuhan
Textile University, Atlantis Press, 2015.