Composite materials (also called composition materials or shortened to composites) are materials made from two or more constituent materials with significantly different physical or chemical properties, that when combined, produce a material with characteristics different from the individual components. The individual components remain separate and distinct within the finished structure. The new material may be preferred for many reasons: common examples include materials which are stronger, lighter or less expensive when compared to traditional materials.
Typical engineered composite materials include:
Composite building materials such as cements, concrete
Reinforced plastics such as fiber-reinforced polymer
Metal Composites
Ceramic Composites (composite ceramic and metal matrices)
Composite materials are generally used for buildings, bridges and structures such as boat hulls, swimming pool panels, race car bodies, shower stalls, bathtubs, storage tanks, imitation granite and cultured marble sinks and counter tops. The most advanced examples perform routinely on spacecraft in demanding environments.
Examples
Concrete is the most common artificial composite material of all and typically consists of loose stones (aggregate) held with a matrix of cement. Concrete is a very robust material, much more robust than cement, and will not compress or shatter even under quite a large compressive force. However, concrete cannot survive tensile loading (i.e. if stretched it will quickly break apart). Therefore to give concrete the ability to resist being stretched, steel bars, which can resist high stretching forces, are often added to concrete to form reinforced concrete.
Fibre-reinforced polymers or FRPs include carbon-fibre reinforced plastic or CFRP, and glass-reinforced plastic or GRP. If classified by matrix then there are thermoplastic composites, short fibre thermoplastics, long fibre thermoplastics or long fibre-reinforced thermoplastics. There are numerous thermoset composites, but advanced systems usually incorporate aramid fibre and carbon fibre in an epoxy resin matrix.
Shape memory polymer composites are high-performance composites, formulated using fibre or fabric reinforcement and shape memory polymer resin as the matrix. Since a shape memory polymer resin is used as the matrix, these composites have the ability to be easily manipulated into various configurations when they are heated above their activation temperatures and will exhibit high strength and stiffness at lower temperatures. They can also be reheated and reshaped repeatedly without losing their material properties. These composites are ideal for applications such as lightweight, rigid, deployable structures; rapid manufacturing; and dynamic reinforcement.
Composites can also use metal fibres reinforcing other metals, as in metal matrix composites (MMC) or ceramic matrix composites (CMC), which includes bone (hydroxyapatite reinforced with collagen fibres), cermet (ceramic and metal) and concrete. Ceramic matrix composites are built primarily for fracture toughness, not for strength. Organic matrix/ceramic aggregate composites include asphalt concrete, mastic asphalt, mastic roller hybrid, dental composite, syntactic foam and mother of pearl. Chobham armour is a special type of composite armour used in military applications.
Additionally, thermoplastic composite materials can be formulated with specific metal powders resulting in materials with a density range from 2 g/cm³ to 11 g/cm³ (same density as lead). The most common name for this type of material is "high gravity compound" (HGC), although "lead replacement" is also used. These materials can be used in place of traditional materials such as aluminium, stainless steel, brass, bronze, copper, lead, and even tungsten in weighting, balancing (for example, modifying the centre of gravity of a tennis racquet), vibration damping, and radiation shielding applications. High density composites are an economically viable option when certain materials are deemed hazardous and are banned (such as lead) or when secondary operations costs (such as machining, finishing, or coating) are a factor.
A sandwich-structured composite is a special class of composite material that is fabricated by attaching two thin but stiff skins to a lightweight but thick core. The core material is normally low strength material, but its higher thickness provides the sandwich composite with high bending stiffness with overall low density.
Wood is a naturally occurring composite comprising cellulose fibres in a lignin and hemicellulose matrix. Engineered wood includes a wide variety of different products such as wood fibre board, plywood, oriented strand board, wood plastic composite (recycled wood fibre in polyethylene matrix), Pykrete (sawdust in ice matrix), Plastic-impregnated or laminated paper or textiles, Arborite, Formica (plastic) and Micarta. Other engineered laminate composites, such as Mallite, use a central core of end grain balsa wood, bonded to surface skins of light alloy or GRP. These generate low-weight, high rigidity materials.
Physical Properties:
The physical properties of composite materials are generally not isotropic (independent of direction of applied force) in nature, but rather are typically anisotropic (different depending on the direction of the applied force or load). For instance, the stiffness of a composite panel will often depend upon the orientation of the applied forces and/or moments. Panel stiffness is also dependent on the design of the panel. For instance, the fibre reinforcement and matrix used, the method of panel build, thermoset versus thermoplastic, type of weave, and orientation of fibre axis to the primary force.
In contrast, isotropic materials (for example, aluminium or steel), in standard wrought forms, typically have the same stiffness regardless of the directional orientation of the applied forces and/or moments.
The relationship between forces/moments and strains/curvatures for an isotropic material can be described with the following material properties: Young's Modulus, the shear Modulus and the Poisson's ratio, in relatively simple mathematical relationships. For the anisotropic material, it requires the mathematics of a second order tensor and up to 21 material property constants. For the special case of orthogonal isotropy, there are three different material property constants for each of Young's Modulus, Shear Modulus and Poisson's ratio—a total of 9 constants to describe the relationship between forces/moments and strains/curvatures.
Techniques that take advantage of the anisotropic properties of the materials include mortise and tenon joints (in natural composites such as wood) and Pi Joints in synthetic composites.
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