Nanocomposites are both man-made and naturally occurring. The reinforcer is generally a nanomaterial such as carbon nanotubes or graphene added to a polymer matrix, or silicon nanoparticles added to steel to induce fine crystal growth. In some applications, calcium carbonate or talc can also be effective in making polymers stiffer and stronger.
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Typical nanocomposites use the nanomaterial additive to add strength, stiffness, and other properties such as electrical or thermal conductivity to the polymer matrix. Naturally occurring nanocomposite examples are bone and shell. Nanomaterials represent significant health risks in some cases, so manufacture of these materials can be challenging.
MMCs use a metal matrix like aluminum or magnesium and a high-strength fiber reinforcer in particle or whisker form. Reinforcers are generally carbon fiber or silicon carbide particles. This develops unique properties that go beyond the basic metal component&#;s limits, including increased strength and stiffness, elevated temperature resistance before the onset of weakening, improved wear resistance, and reduced coefficient of thermal expansion.
MMCs are used in aerospace industries and extreme automotive uses, delivering high strength and low weight. They are also used in electronics, medical devices, and sporting goods. The processing of MMCs is more challenging than most other classes of composites, as high temperatures and the difficulties of uniform reinforcer distribution are challenging.
PMCs are the most prevalent and easily understood forms of composite materials. This term encompasses the hand lay-up of carbon fiber and glass fiber fabrics and the manual, injected, or pre-impregnated epoxies and polyester resins that form the matrix. These materials offer various benefits including high stiffness and strength (compared with the part weight), great thermal, chemical, and mechanical resilience, and abrasion resistance. On the other hand, PMC requires highly skilled labor, resulting in higher costs, though these are often not excessive for applications that need a high-strength outcome.
PMCs are widely used in aerospace, automotive, marine, and sporting goods, benefitting from light weight, high strength, and stiffness. Production of PMCs involves assembly methods such as hand lay-up and filament winding, which can be slow. Precise control over the curing process is needed, to achieve ideal material properties.
GFRPs are a subset of polymer matrix composites, specific to epoxy and polyester bonded glass fiber materials. The glass fiber can be in chopped strands, lending a degree of anisotropic strength to structures by the mixed orientation of the fibers. The reinforcer can also comprise chopped strand roving (or fabric), making a more orderly process but less well suited to bulk components as fibers are all laid in one plane. Woven roving improves the quality of lay-up and can offer greater strength, at a price.
Hybrid composites are those in which two or more different reinforcing fibers are integrated into the final material. This could be a combination of glass and carbon fiber in a lay-up&#;for enhanced impact resistance or cosmetic reasons. It is common to use titanium mesh or strands in the manufacture of racquets for ball sports, to improve tensile and bending performance. These materials can be challenging, as compatibility issues can affect the behavior of the material&#;for example, one fiber may bond better to the matrix than the other. Considerable testing is required to confirm the value or feasibility of the hybrid matrix. They have the same applications as PMCs, but the higher cost restricts their use.
CMCs consist of a ceramic matrix and reinforcing fibers. A ceramic matrix provides extreme temperature and corrosion resistance and excellent wear properties. But ceramics are generally brittle when unreinforced. The addition of silicon carbide, alumina, or carbon fibers can counter the brittleness to make a more serviceable material.
CMCs are used to make gas turbine blades, specialist rocket/aerospace components, and heat exchangers. CMCs are very costly and they remain quite brittle, which limits their use. However, this is a field of intense research, and properties are improving.
There is an increasing trend toward using natural fibers in composite manufacture, to reduce the environmental impact of materials use. Natural fibers such as jute, flax, cotton, and wood are used in a variety of ways. Automotive interior panels are commonly made from resin-bonded natural fibers which are compression molded to shape and then upholstered in plastics or leather for final surfacing. Wood fibers are added to polymers for FDM/FFF rapid prototyping filaments, to improve strength and produce a wood effect. Skateboard decks make extensive use of natural fiber reinforcement, generally in a polyester resin matrix.
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CFRPs are another subset of polymer matrix composites, specific to epoxy and polyester-bonded carbon fibers. For hand lay-up purposes, carbon fiber is generally used as woven roving, with a range of weave patterns used for various types of loading and stress distribution. The fibers are pre-impregnated with thermally activated resins, so the flexible cloth is laid-up and then compressed and baked to liquify and then cure the resin to create a rigid, tough result. Carbon fiber can also be pultruded with a range of polymers, to make continuous lengths of CFRP in complex sections.
AFRPs are another subset of polymer matrix composites that employ aramid as the reinforcer. Aramid fiber composites are used in the highest-impact applications. The aramid is generally used as woven fabrics that are pre-impregnated with appropriate epoxy and polyester resins, to be processed as per carbon/glass fiber. Another aramid reinforced composite is the paper/aramid honeycomb material used in low-profile flooring panels in aviation&#;layered with aluminum sheets and epoxy bonded, this is a typical high-value hybrid composite.
FGCs are essentially a subset of any type of composite. These are composite materials in which the constituent parts can be modified in the application or type through the structure to tune performance. A gradual transition in properties is used to avoid stress concentrations at sudden changes. The functional grading can be as simple as adding or altering fiber content at elevated stress points; changes in weave pattern in roving to alter load distribution; or progressive hybridization for impact resilience in regions.
FGCs are used to make lighter and more resilient aircraft and spacecraft components, such as turbine blades and rocket nozzles. Biomedical devices/implants can have varied properties regionalized according to desired tissue interactions.
Fiber and metal additives in 3D printing materials offer some potential advantages. These are listed below:
Some 3D printing processes use a form of functional grading, by co-printing rigid and elastomeric materials in the same parts, allowing properties to be varied through a build.
There are also challenges in using composites in some 3D printing processes, as listed below:
Listed below are some industrial applications of composite materials:
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You can find different composite materials in the composite material data source under engineering data. You could create or modify one of these materials to have properties of graphite-epoxy. Have a look at this tutorial series 1. https://www.youtube.com/watch?v=oRDJg5ApnmI&list=RDCMUCdymxOTZSP8RzRgFT8kpYpA&index=3 2. https://www.youtube.com/watch?v=5M72kiPe4Ho , 3. https://www.youtube.com/watch?v=uksnwgiBVEg , 4. https://www.youtube.com/watch?v=5mvHCx-qftk , 5. https://www.youtube.com/watch?v=Zp8qp0fYYHo . You could find additional information in the ACP User's Guide. Regards Ishan.
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