Chloe Zhang
Composite materials are those that are made from two or more constituent materials with dissimilar chemical or physical properties. The individual elements remain separate and distinct within the finished structure. Composites can be natural or synthetic, with the latter being the result of the development of resin materials and fiber reinforcements. Synthetic plastic resins include polyester, vinyl ester, epoxy, and phenolic. The process of creating composite plastic materials involves combining and processing the constituents in a pelletizing extruder to form pellets, which are then re-melted and shaped. Alternatively, the finished part can be produced in a single step of mixing and extrusion.
| Characteristics | Values |
|---|---|
| Definition | Any material that consists of two or more materials |
| Examples | Concrete, plywood, Egyptian mud-straw bricks, fibreglass, carbon-fibre-reinforced polymers, glass-reinforced plastic, wood-plastic composites |
| Advantages | Stronger than individual elements, customisable shape, size, and strength, less waste, less maintenance, excellent thermal and electrical insulators, environmentally friendly |
| Disadvantages | N/A |
| Use Cases | Aerospace, automotive, construction, consumer electronics, sporting goods, medical devices and implants, boatbuilding, defence, consumer products, medicine |
| Composition | Binding agent (matrix) and a filler material (fibre or particulate) |
| Manufacturing Process | Mixing wood particles with recycled plastics, combining fibre and resin to make a matrix |
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What You'll Learn
Wood-plastic composites
WPCs are widely used in the US and are manufactured by mixing wood particles as fine as flour with recycled plastics. The manufacturing process for WPCs includes extrusion, injection moulding, and compression moulding or thermoforming (pressing). Newer manufacturing processes include additive manufacturing via fused layer modelling and laser sintering. The extrusion process uses a variety of extruder types, such as single or double screws, to form the final shape of the material. In some manufacturing facilities, the constituents are combined and processed in a pelletizing extruder, producing pellets of the new material, which are then re-melted and formed into the final shape.
The most abundant profiles made from WPCs are boards or lumber used in outdoor decking applications. Other applications include electrical casings, packaging, daily living supplies, and civil engineering applications. WPCs are often considered a sustainable material because they use waste wood and recycled plastic material. They are also low maintenance compared to solid wood and highly resistant to rot, decay, and marine borer attack.
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Reinforcing plastic
Composite materials are those that are made from two or more constituent materials with dissimilar chemical or physical properties. The individual elements remain separate and distinct within the finished structure. Composite materials with more than one distinct layer are called composite laminates.
Reinforced plastics are a type of composite material. They are made up of a binding agent forming a matrix and a filler material that gives the composite substance. The filler material can be particulates or fibres.
An early example of reinforced plastic is the combination of fiberglass and bakelite, performed in 1935 by Al Simison and Arthur D Little at the Owens Corning Company. One of the most common and familiar composites is fibreglass, where small glass fibres are embedded within a polymeric material, usually an epoxy or polyester resin.
Other examples of reinforced plastics include carbon-fibre-reinforced polymers and glass-reinforced plastic. Carbon fibres are held in polymer or plastic matrices, and glass-reinforced plastic is a thermoplastic composite.
Reinforced plastics can also be made from natural materials. For example, wood is a naturally occurring composite made up of cellulose fibres in a lignin and hemicellulose matrix. Engineered wood includes products such as plywood and wood plastic composite.
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Composite laminates
Composite materials are produced by combining two or more constituent materials with distinct chemical or physical properties to create a new material with unique properties. Composite laminates are a specific type of composite material that are composed of multiple layers of fibrous composite materials bonded together layer by layer.
The process of creating composite laminates involves arranging individual plies or layers of fibrous materials in a specific stacking sequence to achieve the desired engineering properties. These properties can include bending stiffness, strength, and in-plane stiffness, which are influenced by the orientation and arrangement of the plies. The fibres used in composite laminates can include materials such as cellulose, graphite, glass, boron, and silicon carbide, while the matrix material may be composed of epoxies, polyimides, aluminium, titanium, or alumina.
The analysis of composite laminates involves classical laminate analysis, which assumes a linear variation of strains resulting from curvature in the thickness direction. This allows for the computation of stresses at specific locations within the laminate using a set of linear equations. The deformation behaviour of laminated composite plates and shells has been extensively studied using theories such as three-dimensional (3D) elasticity theory, equivalent single-layer (ESL) theories, zig-zag (ZZ) theories, and Layerwise (LW) theories.
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Natural vs synthetic composites
A composite material is any material made from two or more constituent materials with dissimilar chemical or physical properties. Composite materials can be natural or synthetic.
Natural Composites
Natural fiber composites (NFCs) are a class of materials that combine natural fibers with a polymer matrix. NFCs have been used for centuries, but advancements in materials science and manufacturing processes have expanded their modern applications. NFCs are often plant-based, but animal fibers like cocoon silkworm or spider silk can also be used. NFCs are renewable, frequently biodegradable, and have a lower carbon impact than synthetic composites. They are also more economical and easier on processing equipment. However, they have lower tensile strength and impact resistance than synthetic composites, and their natural fibers can absorb moisture, affecting their dimensional stability and mechanical properties.
Synthetic Composites
Synthetic composites are traditional fiber-reinforced materials that use synthetic fibers such as carbon and glass fibers. Synthetic plastic resins were first developed in the modern era and have been refined over the decades by chemical companies, scientists, and engineers. Synthetic composites are stronger and more durable than NFCs, but they are more expensive and less environmentally friendly.
Examples of Natural and Synthetic Composites
Concrete, plywood, and Egyptian mud-straw bricks are examples of natural composites. Synthetic composites include carbon-fiber-reinforced polymers and glass-reinforced plastics.
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Advanced composite materials
Advanced composites exhibit desirable physical and chemical properties, including light weight, high stiffness (elasticity), strength along the reinforcing fibre, dimensional stability, temperature and chemical resistance, flex performance, and relatively easy processing. They are also resistant to radiation and fatigue loading.
ACMs are manufactured using expensive, high-performance resin systems and fibre reinforcements. The fibres provide strength and stiffness, while the resin provides shape and protects the fibre. The resin systems used include polyester, epoxy, and other specialty resins.
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Frequently asked questions
Composite plastic materials are those that combine a matrix, usually plastic, with a reinforcing material, typically a fibre.
Composite plastic materials are made from a combination of resin and fibre. The resin provides shape and protects the fibre, while the fibre provides strength and stiffness.
Composite plastic materials are produced by mixing and extruding the constituent materials. In some cases, the materials are combined and processed in a pelletizing extruder, which produces pellets of the new material. These pellets are then re-melted and formed into the final shape.
Examples of composite plastic materials include plywood, medium-density fibreboard (MDF), fibreglass, and carbon-fibre-reinforced polymer.
Composite plastic materials offer several advantages over traditional materials. They can be designed to have higher strength and stiffness ratios for their weight and can be manufactured to custom shapes. They also often require less maintenance and can be more environmentally friendly.
