4.2F COMPOSITES

• Techniek
• Middelbare school
• havo
• Leerjaar 3

4.2F COMPOSITES

Learning Objectives

At the end of the lesson, you will be able to describe the nature and significance of composite materials in modern design. At the end of the lesson, you will understand the concepts and principles behind the form, process, composition, and structure of composites. At the end of the lesson, you will be able to identify the advantages and disadvantages of using composite materials in various design contexts. At the end of the lesson, you will recognize different types of composites such as laminar, fiber-reinforced, and particle-reinforced, and their applications. At the end of the lesson, you will comprehend the role of the matrix in composites and the types of matrices commonly used. At the end of the lesson, you will be familiar with the different manufacturing processes for composites like weaving, molding, pultrusion, and lamination.

What do you already know about composite materials?

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The Role of Composites in Product Design

Forms of composites: fibers/sheets/particles and matrix. Composite manufacturing processes: weaving, molding, pultrusion, lamination. Composition and structure of various composites: concrete, engineered wood, fiberglass, Kevlar®, carbon-reinforced plastic, LVL. 

Pultrusion

Pultrusion is a continuous process used to manufacture fiber-reinforced polymer (FRP) composite profiles with a constant cross section. A composite is a composition material, typically consisting of a thermoset or thermoplastic polymer, reinforced with glass, carbon, aramid fibers, or combinations thereof.

What type of composite is LVL (Laminated Veneer Lumber)?

1. Engineered wood
2. Concrete
3. Fiberglass
4. Carbon-reinforced plastic

What is the composition of Kevlar® composites?

1. Fibers and matrix
2. Only matrix
3. Sheets and particles
4. Only fibers

Which manufacturing process is commonly used for making fiberglass composites?

1. Lamination
2. Weaving
3. Pultrusion
4. Molding

Forms of Composites

Composites are materials made by combining two or more distinct materials to harness their unique properties.

 Main components: reinforcement (fibers, sheets, or particles) and matrix (thermoplastics, thermosets, ceramics, or metals). Laminar, fiber-reinforced, and particle-reinforced composites. Specific applications based on mechanical, electrical, physical, and chemical properties.

Composition and structure of composites

Concrete – water, Portland cement, and aggregates (gravel etc)

Composition and structure of composites

Engineered wood – also called composite wood, man-made wood, or manufactured board. gluing sheets (veneer), particles or stands of wood together.

• Plywood – sheets of venner glued together with the grain perpendicular to each sheet.
• Particleboard – chips of wood glued together (see above image).

Composition and structure of composites

Fibreglass – stands of glass, formed into a matt and then covered in resin (polymer/thermoset plastic)

Composition and structure of composites

Carbon- reinforced plastic – carbon fibres formed into a matt (see above image) then covered in resin.

Kevlar® – para-aramid synthetic fiber covered in a resin

Laminated veneer lumber (LVL) – uses multiple layers of thin wood assembled with adhesives

Composite Manufacturing Processes

Weaving, molding, pultrusion, and lamination are used to create composite products. Each process has its unique advantages and is suitable for different types of composites and applications.

Composition and Structure of Various Composites

Concrete, engineered wood, fiberglass, Kevlar®, carbon-reinforced plastic, LVL. Each composite has specific properties and is used in various design contexts based on its unique characteristics.

Advantages and Disadvantages of Composite Materials

Strength-to-weight ratio, molded into complex shapes. Costly and difficult to repair. Specific advantages and disadvantages based on the type of composite and its application.

Applications of Composite Materials in Design

Various applications in aerospace, automotive, construction, marine, sports equipment, and consumer goods. Each type of composite is used based on its specific properties and benefits in a particular design context.

Applications of Composite Materials in Design

Advantages of composite materials: 

●Improved properties 

●Reduced weight  

Disadvantages of composite materials: 

● Difficulty of repair 

● Cost 

Definition List

Composite material: A material made by combining two or more different materials to create a new material with unique properties. 

Matrix: The continuous material in a composite that holds the reinforcement in place and helps transfer loads. Laminar composites: Composites made of layers bonded together, such as plywood and laminated glass. 

Fiber-reinforced composites: Composites containing fibers as the reinforcement, providing high tensile strength. Particle-reinforced composites: Composites with particles embedded in a matrix, such as concrete with gravel aggregate. 

What are laminar composites made of?

1. Layers bonded together
2. Individual fibers bonded together

What is a composite material?

1. A material made by combining different materials
2. A material made from a single material

Definition List

Thermoplastics: A type of polymer that becomes pliable or moldable above a specific temperature and solidifies upon cooling. Thermosetting plastics: A polymer that irreversibly cures forming a rigid structure through a curing process like heat or a chemical reaction. Ceramics: Inorganic and non-metallic materials that are typically hard and brittle. Metals: A class of elements characterized by good electrical and thermal conductivity as well as malleability and ductility.

Which class of elements is characterized by good electrical and thermal conductivity?

1. Metals
2. Ceramics

What is a characteristic of thermosetting plastics?

1. Becomes pliable or moldable above a specific temperature
2. Irreversibly cures forming a rigid structure

Write down 3 things you learned in this lesson.

Have students enter three things they learned in this lesson. With this they can indicate their own learning efficiency of this lesson.

Write down 2 things you want to know more about.

Here, students enter two things they would like to know more about. This not only increases involvement, but also gives them more ownership.

Ask 1 question about something you haven't quite understood yet.

The students indicate here (in question form) with which part of the material they still have difficulty. For the teacher, this not only provides insight into the extent to which the students understand/master the material, but also a good starting point for the next lesson.