Composite Materials: Benefits, Types, and Properties

Recently, most of the products on the market are made of synthetic materials. This is for good reason, as synthetic materials give prime strength and endurance, making them durable and ideal for various purposes.

One of the synthetic materials widely used in industries is a composite material. It offers better strength and versatility. This article reveals the definition of a composite material and its difference from standard plastics. Thus, read this article until the end.

What Is a Composite Material?

A composite material is made by combining two or more different materials to produce more enhanced properties than using single materials.

The combining process of these materials does not alter their individual properties. Each material retains its own characteristics, allowing them to complement one another and produce a material that is stronger, lighter, or more durable, depending on the intended application.

The history of a composite material dates back to 3400 BC. The first man-made composites were created by the Mesopotamians in Iraq. They bonded sheets of wood with glue to form plywood.

Later, the Egyptians began making masks from papyrus or linen soaked in plaster in 2181 BCE. Both of these civilizations reinforced their materials with straw to improve the performance of pottery and jewelry.

In 1200 AD, the Mongols made composite bows from wood, bone, cow tendons, animal horns, and silk bonded with pine resin.

Then, in the 1930s, composites began to develop. During that period, Owens Corning invented fiberglass. It was later used to create the industry’s first fiber-reinforced polymer (FRP).

In the mid-90s, manufacturing and construction processes began using composites because they were more cost-effective than the previously used materials.

Understanding Natural and Man-made Composite Materials

Did you know? Composites are not always man-made. Naturally, organism parts are also composites. For example, wood consists of cellulose fibers bound together by lignin (a complex organic polymer as the main adhesive and component of plant cell walls along with cellulose). Additionally, the bones of living organisms are made of hydroxyapatite, which consists primarily of calcium phosphate and collagen.

Furthermore, most man-made composites contain two materials: a matrix and reinforcing materials (like fibers). The matrix protects fibers from damage and helps spread load between fibers.

In addition, fibers provide rigidity and tensile strength as well as holding it from breaking. In industrial sectors, the matrix comes from polyester resins, while the reinforcing material is glass fibers. Even so, there are many composite combinations out there customized to the needs.

One of the common examples of man-made composites is concrete. This material consists of sand, cement, and aggregates. Concrete can also be reinforced by adding wire or metal rods, resulting in a construction material known as reinforced concrete. Adding metal rods to concrete boosts its strength.

How Is a Composite Material Made?

In general, composite materials are manufactured in three stages. Here is a brief explanation:

Reinforcing layers are arranged in a controlled manner to form a stable and strong foundation. These layers typically consist of fibers.
The fiber structure and binder (such as resin) are pressed into a mold so that they bond together and form the desired product.
The fibers are drawn through liquid resin and a heated mold. This process produces a consistent product.

These three main processes result in a stable, strong, and uniform composite that can be used in other manufacturing processes. Aside from these processes, composite materials can also be produced using other methods, such as compression molding, filament winding, injection molding, 3D printing, and others.

Composite Materials’ Properties

Composite materials usually have several properties, such as:

Tough tensile strength.
Stable rigidity.
Reliable fatigue resistance.
Low density.
Stable in size.
Consistent physical pattern.
Resistance to corrosion, humidity, chemicals, and solvents.
Excellent load-bearing.
Deformation-resistant.
Has a controlled and balanced reaction between resin and fibers.
Resistance to extreme weather.
Resistance to repetitive pressure, like vibration and shock.
Impact-resistant.

Types of Composite Materials

There are various types of composite materials used in many sectors, such as construction and industry. Here are several of them:

1. Glass Fiber-Reinforced Plastic (GFRP)

GFRP is widely known as fiberglass, though fiberglass is considered a component of GFRP. You can find GFRP in pipelines and storage tanks.

2. Metal Matrix Composite (MMC)

MMC uses metals (titanium, magnesium, or aluminum) as a matrix, while alumina, carbon fiber, steel, or silicon carbide is used as a reinforcing material.

MMC is characterized by its resistance to expansion at high temperatures, its strength, and its ability to retain its shape under prolonged loads and temperatures without deforming. MMC is used in vehicle bodies, sports equipment, and gearboxes.

3. Ceramic Matrix Composite (CMC)

CMS uses ceramic as a matrix and reinforcing material. It has excellent corrosion resistance. CMC is commonly used in machinery, vehicle brakes, and turbines.

4. Carbon Fiber-Reinforced Polymer (CFRP)

CFRP has a particular black hatching pattern. Usually, it contains carbon fibers and resins (polyesters and epoxies). CFRP is malleable, making it more versatile. You can find CFRP in electronic parts, automotive parts, sports gear, and medical equipment.

Is Plastic Also Composite?

Not all plastics are composite. There are also pure plastics without any mixed materials. Composites have a clear difference from standard plastics.

For example, composites rely on a reinforced matrix to acquire better strength compared to standard plastics. They are also more rigid and heat-resistant. The manufacturing process is also more complex than plastics.

However, this does not rule out the possibility of plastic being used in composite materials. One example of composite plastic is aramid fiber-reinforced plastic, which is available in bulletproof vests and helmets. Also, epoxy and polyester can be reinforced to make them more durable and strong yet still maintain the plastic property.

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