Introduction……………………………………………………………………………..

1.1-…………………………………………………………………………………….
1.2-………………………………………………………………..
1.3- Classification composite materials…………………………………………………
1.4-Composents…………………………………………………………………….
1.4.1-…………………………………………………………………..
1.4.2……………………………………………………………….
1.4.3-……………………………………………………………….
1.4.4…………………………………………………………………
1.5-Advantages and Disadvanges of composite…………………………………………………..
1.6-
1.6.1
1.6.2
1.6.3
1.7-Application of composite materialk
 Chapter01
Introduction of composite materials
Introduction:
A composite is combination of two materials in which one of the materials, called the reinforcing
phase,is in the form of fibers, sheets, or particles, and is embedded in the other materials called the
matrix phase. The reinforcing material and the matrix material can be metal, ceramic, or polymer.
Compositestypically have a fiber or particle phase that is stiffer and stronger than the continuous
matrix phase and serve as the principal load carrying members. The matrix acts as a load transfer
medium between fibers,and in less ideal cases where the loads are complex, the matrix may even
have to bear loads transverse tothe fiber axis. The matrix is more ductile than the fibers and thus
acts as a source of compositetoughness. The matrix also serves to protect the fibers from
environmental damage before, during andafter composite processing. When designed properly, the
new combined material exhibits better strengththan would each individual material. Composites are
used not only for their structural properties, butalso for electrical, thermal, tribological, and
environmental applications.

1.1-Definition:
A composite material is made up of the combination of two or more materials of different natures.
Their complementary association results in a material whose desired performance will be superior
to that of the individual components taken separately. In the most general case, a composite
material consists of one or more discontinuous phases distributed within a continuous phase. The
discontinuous phase, called the reinforcement or reinforcing material, is typically harder with
superior mechanical properties compared to the continuous phase, known as the matrix.

1.3- Classification of Composite Materials:

According to the nature of the matrix, three main classes of composites can be distinguished, listed
here in order of increasing temperature resistance:

 Polymer Matrix Composites (PMC)

 Metal Matrix Composites (MMC)
 Ceramic Matrix Composites (CMC)

The materials used as reinforcements exhibit good intrinsic mechanical properties (carbon, alumina,
silica, boron, Kevlar, steel, silicon nitride, and silicon carbide, among others). Continuous
reinforcements or long fibers have a diameter that varies depending on their nature, ranging from a
few micrometers to around a hundred micrometers.

Depending on the intended application, the assembly of these long fibers can be one-dimensional
(unidirectional plies), two-dimensional (woven plies, mats made of chopped fibers a few
centimeters long or continuous fibers), or three-dimensional (multidimensional fabrics).

Polymer matrices reinforced with glass fibers are widely used in mass-produced products and hold
significant importance. Carbon fibers and Kevlar are used for more specialized high-performance
applications such as aeronautics and aerospace. Other types of reinforcements are also employed,
such as beads (glass, elastomer, etc.) and fillers (crushed fibers, flakes, powders, etc.). The use of
Polymer Matrix Composites (PMC) remains limited to temperature ranges below 200°C.

1.4-components:
Composite materials are made up of two or more distinct components that work together to create a
material with enhanced properties compared to the individual components. The primary
components of composite materials are:

1.4.1- Matrix (Continuous Phase)

 The matrix is the base material that surrounds and binds the reinforcement together.
 It transfers loads to the reinforcement, protects it from environmental damage, and provides
shape to the composite.
 Types of matrices:
o Polymer Matrix: Thermosets (e.g., epoxy, polyester) or thermoplastics (e.g., nylon,
polyethylene).
o Metal Matrix: Aluminum, titanium, magnesium, etc.
o Ceramic Matrix: Silicon carbide, alumina, etc.

2. Reinforcement (Discontinuous Phase)

 The reinforcement provides strength, stiffness, and other mechanical properties to the
composite.

 It is typically harder and stronger than the matrix.

 Types of reinforcements:
o Fibers: Continuous or short fibers (e.g., glass fibers, carbon fibers, Kevlar, boron
fibers).

o Particles: Fine particles (e.g., silicon carbide, alumina).

o Whiskers: Tiny single-crystal fibers (e.g., silicon carbide whiskers).

o Flakes: Thin, flat particles (e.g., mica, glass flakes).

o Fillers: Used to modify properties (e.g., talc, clay).

3. Interface

 The interface is the boundary between the matrix and the reinforcement.

 It plays a critical role in ensuring effective load transfer and bonding between the matrix and
reinforcement.

 A strong interface is essential for optimal composite performance.

4. Additives (Optional)

 Additives are sometimes included to enhance specific properties of the composite, such as:
o Plasticizers: Improve flexibility.

o Stabilizers: Enhance thermal or UV resistance.

o Flame Retardants: Improve fire resistance.

 o Colorants: Add aesthetic appeal.

Summary of Key Components:

Component Role Examples

Binds reinforcement, transfers load, protects

Matrix Epoxy, aluminum, silicon carbide
reinforcement

Reinforcemen
Provides strength, stiffness, and mechanical properties Carbon fibers, glass fibers, Kevlar
t

Ensures bonding and load transfer between matrix and Coating or surface treatment of
Interface
reinforcement fibers

Plasticizers, stabilizers, flame

Additives Enhances specific properties (optional)
retardants

By combining these components, composite materials achieve superior properties such as high
strength-to-weight ratio, corrosion resistance, and tailored mechanical performance for specific
applications.

I.5 Advantages and Disadvantages of Composites

Composites are preferred over other materials because they offer advantages related to:

 Lightweight

 High fatigue resistance

 Low aging under the effects of humidity, heat, and corrosion

 Insensitivity to chemicals

 Ability to take on complex shapes (complex parts)

 Good fire resistance (though caution is needed regarding toxic emissions)

However, certain disadvantages limit their widespread adoption:

 High costs of raw materials and manufacturing processes

 Sensitivity to heat

 Challenges in waste management and increasingly strict regulations.

1. 6 Structural Composite Materials

The structures of composite materials can be classified into three types:

 Single-layer (Monolayer)
  Laminated

 Sandwich

I.6.1 Single-layer (Monolayer)

Single-layer composites represent the basic element of composite structures. The different types of
single-layer composites are characterized by the form of the reinforcement:

 Long fibers (unidirectional UD, randomly distributed),

 Woven fibers,

 Short fibers.

Stratified Composites

A stratified composite is made up of a stack of individual layers, each with its own orientation
relative to a common reference frame shared by all layers, known as the composite's reference
frame.

By adjusting the order and orientation of these layers, it is possible to finely tune the mechanical
properties of the composite to match external loads. This allows for a high level of optimization by
placing material where it is most effective.

Sandwich Structures

Sandwich structures are composite materials consisting of two stiff and thin face sheets (or skins)
enclosing a thick and low-strength core.

The combination forms a highly lightweight structure. Sandwich materials exhibit excellent flexural
lightness and provide outstanding thermal insulation properties.

1.8Applications of Composite Materials:

 Aerospace: Aircraft wings, fuselages, and spacecraft components.

 Automotive: Body panels, chassis, and interior components.
 Construction: Bridges, buildings, and pipelines.
 Marine: Boat hulls, decks, and offshore structures.
 Sports Equipment: Bicycles, tennis rackets, and golf clubs.
 Medical: Prosthetics, dental materials, and imaging equipment.
 Chapter02
Techniques of making composite material
Introduction…………………………………………………………………………………………

1-Composite manufacturing techniques……………………………………………………

1.1-Open mould process…………………………………………………………………

1.1.1-Definition……………………………………………………………………………………

1.1.2-Type of open mould process………………………………………………………

1.2.1-Hand lay-up process………………………………………………………………

1.2.2-Spray-up process…………………………………………………………………

1.2.3-Filament winding……………………………………………………………………

1.2-Close mould process……………………………………………………………………

1.2.1-Definition……………………………………………………………………………………

1.2.2-Type of close mould process…………………………………………………………

2.2.1-Resin Transfer molding(RTM)………………………………………………

2.2.2-Vacum assisted resin transfer molding (VARTM)…………………………

2.2.3-Compression molding ………………………………………………………………

 2.2.4-Pultrusion……………………………………………………………………………

2.2.5-Injection molding……………………………………………………………………

2.Future overview………………………………………………………………………………..

Conclusion…………………………………………………………………………………………

Introduction:

To put it simply, composite manufacturing is the process required to produce the final composite
material. There are a number of techniques available and the chosen composite manufacturing
method will always be driven by the final desired output, taking into consideration the materials
needed as well as design.

1. Composite manufacturing techniques:

Thanks to advances in composites manufacturing and process design there are a range of ways to
manufacture composites. the route to a final composite material which is fit for purpose is often
bespoke This ensures that the finished product matches the specifications for the particular project.
There are two types of methods for manufacturing composite materials:

1-Open mould process

2-Closed mould process

1.1.Open mould process:

1.1.1 Definition:

Open mould processes are a group of manufacturing techniques used primarily in the production of
composite materials, such as fiberglass, carbon fiber, and other reinforced plastics. These processes
involve the use of a single-sided mould (open mould) to create the desired shape of the product. The
reinforcement material (e.g., fiberglass) is placed onto the mould, and resin is applied to bind the
fibers together, forming the final composite structure. Open mould processes are widely used in
industries such as automotive, marine, aerospace, and construction due to their flexibility and cost-
effectiveness.

1.1.2 Type of open process:

Here are the most common open mould processes:

1-Hand lay-up process.

2-Spray-up process.
3-Filament Winding.

1.2.1 Hand Lay-Up Process:

1. Method:
Initially a thin layer of release gel is applied on the bottom of the mold surface for easy extraction
of composite materials.

Then, fiber preforms are placed in a mold.

The resin material is poured or applied using a brush on a reinforcement material.

The brush or roller is used to impregnate the resin into the fabrics to ensure an enhanced interaction
between the successive layers of the reinforcement and the matrix materials. Processes involved in
the hand lay-up are shown in figure(2-1).

Figure (2-1): Hand lay-up Process.

2. Advantage:

 Cost of production equipment is very low.

  Simplest metode.

 Design changes are readily made.

3. Disadvantage:

 The process is time consuming.

 Environmental problems can rise during the working procedure.

 The composite will have a smooth surface on one side and a very rough surface on the other.

4. Application:
 Train nose-Train control console-Motor boat-Manufacturing of aircraft wings -
Swimming pools etc.

1.2.2 Spray-Up Process:

1.Method:
Liquid resin and chopped fibers are sprayed onto an open mold to build successive FRP laminations
.Attempt to mechanize application of resin-fiber layers and reduce lay-up time Alternative for step
(3) in the hand lay-up procedure

Figure (2-2): Spray-Up Process.

2. Advantages:

 The spray-up process offers the following advantages:

  It is suitable for small to medium-volume parts.

 It is a very economical process for making small to large parts.

 It utilizes low-cost tooling as well as low-cost material systems.

3. Disadvantages:

 It is not suitable for making parts that have high structural requirements. It is difficult to
control the fiber volume fraction as well as the thickness.

 The process offers a good surface finish on one side and a rough surface finish on the other
side.

 The process is not suitable for parts where dimensional accuracy and process repeatability
are prime concerns.

 The spray-up process does not provide a good surface finish.

 Only short fibres can be used in this process.

 Similar to wet/hand lay-up process, the resins need to be of low viscosity so that it can be
sprayed.

4. Application:

 Simple enclosures, lightly loaded structural panels, c.g. caravan bodies, truck fairings,
bathtubs, shower trays, some small dinghies.

1.2.3 Filament Winding:

1.Method:
Resin-impregnated continuous fibers are wrapped around a rotating mandrel that has the internal
shape of the desired FRP product, the resin is then cured and the mandrel removed. The fiber
rovings are pulled through a resin bath immediately before being wound in a helical pattern onto the
mandrel. The operation is repeated to form additional layers, each having a criss- cross pattern with
the previous, until the desired part thickness has been obtained
 Figure (2-3): the filament winding process.
2. Advantage:

 Filament winding is automated

 The labor charges for filament winding is lower than other open molding processes.

3. Application:

 Cylindrical products such as pipes. cylinders etc are produced.

1.2 Closed Mould Process:

1.2.1 Definition :
The closed mould process is a manufacturing technique used primarily in composite materials
production . It involves using a two-part mold (a mold with a top and bottom half) that encloses the
material completely during the shaping or curing process. This method is widely used in industries
like automotive, aerospace, and consumer goods for producing high-quality, consistent parts.
1.2.2 Type of closed mould process:
Here are the most common closed mould processes

 Resin Transfer Molding (RIM).

 Vacuum assisted resin transfer Molding.
 Compression molding.
 Pultrusion.
 Injection molding.

2.2.1 Resin Transfer Molding:

1.method:
Resin transfer molding is excellent for mass production of composite parts. A two-part, matched-
metal mold (or tool) is prepared. The fibers / fabric is placed on the bottom half of the mold. Then
the mold is closed and resin is then pumped under low pressure through injection ports into the
mold, after all the fibers/fabric is wet out, the resin inlets are closed and the laminate is allowed to
cure at the room temperature.

2. Advantage of resin transfer molding:

 The process produces good finished sides of the composites.

 Process is less time taking

3. Disadvantage of resin transfer molding:

 Initial cost for manufacturing the molds is high.

4. Application:
 Automotive parts, lower volume parts of the aerospace industry are produced by this method

2.2.2 Vacuum Assisted Resin Transfer Molding:

1.Method:
 Vacuum assisted resin transfer molding
2. Advantages:

 Vacuum bag processing can produce laminates with a uniform degree of consolidation,

 Vacuum assisted wet lay helps to prevent the presence of voids, caused by air trapping.

 Low pressure removes the entrapped air, thus reducing the void content.

 Molds used in VARTM are similar to those used for conventional open-mold processes

3. Disadvantage:

 It is a relatively complex process to perform well.

 Due to the complex nature of the VARTM process, the rial and error method is expensive
for the process design and optimization.

2.2.3 Compression molding;

1.Method:
 It uses preheated molds mounted on a hydraulic or mechanical press.

 A prepared prepreg is placed in between the two halves of the mold, which are then pressed
against each other to get a desired shape of the mold.

 Generally, compression molding process have two steps,

1. Preheating 2. Pressurizing.

 Prepreg is placed in a cavity of fixed mold in open position

 Mold is closed by means of hydraulic action.

 Pressure is exerted to squeeze the resin so that it fills the mold cavity.

 Heat is applied in the mold.

 Because of temperature and pressure, the resin is cured.

Types of Compression Molding:

Sheet molding compound:

Sheet molding process involves placing a reinforcement, such as a glass mat, between sandwiching
layers of a thermoplastic and heating the materials to produce a single sheet of materials.

Bulk molding compound:

Bulk molding compounds by producing a billet of molten material that is placed into a compression
molding press which molds the molten material into a part.

Figure (2-1): Compression molding Process.

2. Advantagas:

 Short cycle time.

 High degree of productivity.

 Automated process.

 Good dimensional accuracy.

  Low cost.

 Improved impact strength.

3. Disadvantages:

 Large curing time.

 Parting line present on the final product.

 Scrap cannot be reprocessed.

3. Applications:

 automobile components, electrical components etc are produced by using BMC and SMC.

2.2.4 Pultrusion:

1.Method:

Pultrusion is a continuous process for the manufacture of composites having a

constant cross section. Many creels (balls of roving are positioned on a rack. The
series of tensioning devices and roving guides direct the roving into the heated die.
Continuous strand of fiber roving, is impregnated in a resin bath, then pulled (pul-
trusion) through a steel die,

Figure (2-7): Pultrusion process.

2. Advantages:

 The process is a continuous operation and it is automated.

 It is adaptable to both simple and complex cross-sectional shapes.

3. Application:

 products having a constant cross section, such as rods, beams, fishing rods, golf club shafts
 etc.

2.2.5 Injection Moulding:

1)-Method:

The thermoplastic polymer or thermoset plastic polymer is heated by extemal heat source in the
hopper. Wood fiber usually in the form of the flour or very short staple fibers is added to the
polymer. The constituent is thoroughly mixed. The compound is ready to be extruded into the final
product. The compound is transferred from the hopper to the extruder where it is injected in the
mold cavity. The prepeg is cooled and hardened. The part is then ejected from the mold. Injection
molding is a fast, process capable of producing up to 2000 small parts per hour.

Figure (2-7): Injection moulding process.

2)-Advantages of injection moulding:
 High precision and accuracy in producing complex parts.
 High production efficiency and repeatability.
  Wide range of materials can be used

3)-Disadvantages of injection moulding:

 High initial tooling cost.

 Limited to parts with relatively small sizes.
 Not suitable for low-volume production.

4. Application:

 Injection moulding is widely used for manufacturing a variety of parts, from the smallest
component to entire body panels of cars, bathing tubs etc.

2. Future overview:

A significant leap in the development of composite manufacturing technologies might not be really
foreseeable in the near future. However, a lot of improvement in the current manufacturing method
is currently being studied and a few new manufacturing concept are in the progress. The
introduction of the automated tape lay-up (ATL) and the automated fibre placement (AFP), for
examples, indicates the integration of computer-guided-robotic with current composite material to
perform lay-up process for large composite parts such as aircraft wing skin and fuselages. With this
development, it opens up another opportunity for current manufacturing method to be integrated
with automation such as spray-up and filament winding. With the view that natural fibres are
becoming more substantial nowadays to replace depleting petroleum based products such as carbon
fibres, emphasize should be given to the development of manufacturing technology to suit with bio-
sourced hybrid composite material. This is to ensure the sustainability of the whole manufacturing
ecosystem as well as the dependency on the synthetic materials.

Conclusion:

In last two decade use of composite increased rapidly and the same time manufacturing of the
composite also dominate market of advance material, Coast of the product is mainly depend of upon
the two major part, material and manufacturing.

In this chapter basic information of deferent type of manufacturing techniques is discussed. This
chapter helps to understand the basic concept of composite material manufacturing Nowadays we
are looking for less human afford and less human skill techniques, so this chapter help reader to
select best technique to their work.
References:
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350824171_Different_method_of_Fabrication_of_composite_material-
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