Skip to main content
SpringerLink
Log in

Some physical defects arising in composite material fabrication

  • Review
  • Published:
Journal of Materials Science Aims and scope Submit manuscript

Abstract

A fairly wide range of physical defects arising during the processing of composite materials is surveyed. The kinds of composites discussed are fibre-reinforced materials, metal-matrix composites, ceramic-matrix composites and bonded sandwich (clad, rolled) materials. The list of defects considered is not exhaustive but the defect phenomena described exemplify the practical value of a knowledge of the difficulties encountered in composite material processing.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Log in via an institution

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Institutional subscriptions

Similar content being viewed by others

References

  1. W. Johnson, Proceedings of the 3rd International Conference on Mechanical Behaviour of Materials, Cambridge, August, 1979 (Pergamon Press, Oxford, 1980) pp. 167–225.

    Google Scholar 

  2. W. Johnson andA. G. Mamalis, Proceedings of the 17th International Machine Tool Design and Research Conference, Birmingham, 1976 (Macmillan, London, 1977) pp. 607–21.

    Google Scholar 

  3. M. Cohen (Ed)., Material Science and Engineering: Its Evolution, Practice and Prospects (Special issue) 37 (1979).

  4. E. Amini andP. A. Aback,Sheet Met. Ind. 51 (1974) 7.

    Google Scholar 

  5. A. K. Green andW. H. Bowyer, Fibre Reinforced Composites, Engineering Apr. (1977), Technical File, No. 40.

  6. Y. B. Cohen, E. Harnik, M. Meron andR. Davidson,Mater. Evaluation 37 (1979) 51.

    Google Scholar 

  7. S. P. Prosen, “Fibre Composite Materials” (American Society for Metals, Metals Park, Ohio, 1977) p. 157.

    Google Scholar 

  8. D. J. Hagemaier andR. H. Fassbinder, Nondestructive Testing of Advanced Composites, Proceedings of the 1978 Society of Automotive Engineers Aerospace Meeting, San Diego, California, November 1978 (Douglas Paper 6774).

  9. G. Dorey, G. R. Sidey andJ. Hutchins,Composites 9 (1978) 25.

    Google Scholar 

  10. G. Dorey, Proceedings of the AHS/NASA-Ames Conference on Helicopter Structures Technology, November, 1977 (HMSO, London).

    Google Scholar 

  11. Idem, Fracture Behaviour and Residual Strength of Carbon Fibre Composites Subjected to Impact Loads, AGARD Conference Proceedings 163, Munich. October, 1974, B3-1.

  12. S. Tang,Mech. Eng. 99 (1977) 36.

    Google Scholar 

  13. P. F. Thomason,J. Mech. Phys. Sol. 20 (1972) 19.

    Google Scholar 

  14. J. W. Young, Jr, andT. A. Dougherty, Application of Composite Materials for Fabrication of Spacecraft Communication Antennas, Proceedings of the 17th IAF, October 1976, Anaheim, California (Paper 233).

  15. G. S. Pisarenko, V. P. Nannenko andG. S. Volkov,Problemy Prochnostic 9 (1977) 3.

    Google Scholar 

  16. T. Hirai andT. Kimura, Impact Bending Behaviour of Fibre Reinforced Composites, Proceedings of the 2nd International Conference on Composite Materials, April, 1978, Toronto, Canada (Metallurgical Society of AIME, Warrendale, Pa, 1978).

    Google Scholar 

  17. L. E. Malvern, R. L. Sierakowski andC. A. Ross, Impact Failure Mechanisms in Fibre-Reinforced Composite Plates, High Velocity Deformation of Solids, Proceedings of the International Union of Theoretical and Applied Mechanics Symposium, August 1977, Tokyo.

  18. R. L. Sierakowski, L. E. Malvern andC. A. Ross, Dynamic Failure Modes in Impacted Composite Plates, Proceedings of the American Institute of Mechanical Engineers Meeting, February, 1976, Las Vegas, USA.

  19. C. A. Ross, N. Cristescu andR. L. Sierakowski,Fibre Sci. Tech. 9 (1976) 177.

    Google Scholar 

  20. O. Okuno andI. Miura,Jap. Soc. Met. 39 (1975) 1261.

    Google Scholar 

  21. P. J. Cavano, Resin/Graphite Fibre Composites, NASA CR-121275, 1974.

  22. D. Roylance,J. Comp. Mater. 14 (1980) 111.

    Google Scholar 

  23. F. W. Davies, Spallation Threshold of Selected Ablative Concept Materials, Army Materials and Mechanics Research Centre, Contractor Report, 72–11 (1972).

  24. A. R. Champion, W. H. Krueger, H. S. Hartman andA. K. Dhingra, Fibre FP Reinforced Metal Matrix Composites, Proceedings of the 2nd International Conference on Composite Materials, April 1978, Toronto, Canada. (Metallurgical Society of AIME, Warrendale, Pa, 1978).

    Google Scholar 

  25. W. A. Compton andK. P. Steward, Compatibility Considerations for Metal-Matrix Compo-Society of Automotive Engineers Paper 670862, 1967.

  26. A. G. Metcalfe andG. K. Schmitz, Development of Filament Reinforced Titanium Alloys, Society of Automotive Engineers Paper 670862, 1967.

  27. A. Kandeil, J. P. Immariegon andW. Wallace, National Research Council, Canada, Aero. Eng. Rep. LR-595 (1978).

  28. D. M. Royster, H. R. Wiant andR. R. McEithey, NASA Technical Paper 1121, 1978.

  29. D. M. Royster, H. R. Wiant andT. T. Bales, NASA Technical Memo X-3282.

  30. P. H. Thornton,J. Comp. Mater. 13 (1979) 247.

    Google Scholar 

  31. M. Kh. Shorshorov, L. M. Ustinov, A. M. Zirlin, V. I. Olefirenko andL. V. Vinogradov,J. Mater. Sci. 14 (1979) 1850.

    Google Scholar 

  32. D. M. Karpinos, G. G. Maksimovich, E. M. Liutyi, A. V. Filipovski andV. Kh. Kadyrov,Broshkovaya Metal (1978) 44.

  33. A. K. Dhingra, A. R. Champion andW. H. Krueger, Fibre FP Reinforced Aluminium and Magnesium Composites, Proceedings of the First Metal Matrix Composite Workshop, September 1975, Institute of Defence Analyses, Washington, DC, p. C-501.

    Google Scholar 

  34. K. M. Prewo, Fabrication and Evaluation of Low-Cost Alumina Fibre Reinforced Metal Matrices, United Technologies Research Centre, East Hartford, Connecticutt, Report UTRC/R77-912245-3, Contract N00014-76-C-0035, (May, 1977).

  35. J. F. Bacon, Development of Radome Material, United Technologies Research Centre, East Hatford, Connecticutt, Report UTRC/R77-912547-13, Contract F33615-76-C5199, (June, 1977).

  36. D. M. Goddard, Interface. Reactions During Preparation of Aluminium Composites by the Sodium Process, The Aerospace Corporation, El Segundo, California, 90245, Report No. ATR-77 (8162)-3 (20 July 1977).

  37. D. M. Goddard, W. C. Harrigan, D. L. Dull andM. F. Amateau, Fibre-reinforced Lead Composites: Their Preparation and Potential Applications, Aerospace Corp. Report No. ATR-78(8162)-2, (November, 1977).

  38. W. A. Compton, R. J. Atkins andH. Mnew, Metal Matrix Composite Materials for Aircraft Compressor Blades, Proceedings of the 10th SAMPE Symposium, November, 1976, p. C61.

  39. C. G. Levi, G. J. Abbaschian andR. Mehrabian,Metallurgical Transactions 9A (1978) 697.

    Google Scholar 

  40. C. G. Levi, G. J. Abbaschian andR. Mehrabian, in “Rheocasting”, edited by R. D. French and F. S. Hodi (MCIC Report 78-35, Columbus, Ohio, 1978) pp. 41–51.

  41. R. L. Pinckney andA. K. Dhingra, Design and Fabrication of High Modulus Fibre-stabilized Magnesium Transmission Cases, Fourth Conference on Fibrous Composites in Structural Design, San Diego, California, November, 1978.

  42. M. K. White andM. A. Wright,J. Mater. Sci. 14 (1979) 653.

    Google Scholar 

  43. W. H. Kim, M. J. Koczak andA. Lawley, Effects of Iso-thermal and Cyclic Exposures on Interface Structure and Mechanical Properties of FPα-Al2O3/Aluminium Composites, AIME Conference, October, 1978, St. Louis, Montana.

  44. A. Pattnaik, M. J. Koczak andH. C. Rogers, Compressive Failure Behaviour of FP Alumina/Aluminium Composites, AIME Conference, October, 1978, St. Louis, Montana.

  45. J. A. Dicarlo andJ. E. Maisel, High Temperature Dynamic Modulus and Damping of Aluminium and Titanium Matrix Composites, NASA Technology Memo 79080, presented at the AIME Symposium of Advanced Fibres and Composites for Elevated Temperatures, February, 1979, New Orleans.

  46. G. C. Olsen, Thermal Exposure Effects on the Mechanical Properties of a Polycrystalline Alumina Fibre/Aluminium Matrix Composite, presented at the 24th National SAMPE Symposium and Exhibition, May, 1979, San Francisco, California.

  47. R. Crampton, Hydrodynamic Lubrication and Coating of Wire Using a Polymer Melt During Drawing Process, Ph.D. Thesis, Dept. of Mechanical and Production Engineering, Sheffield City Polytechnic, 1980.

  48. M. Moss, W. R. Hoover andD. M. Schuster, “Metal-Matrix Composites of Closed Geometries”, (Plenum Press, New York, 1979) p. 425.

    Google Scholar 

  49. H. Gigerenzer, R. T. Pepper andW. L. Lachman, Hot Drawing of Fibre (Filament) Reinforced Metal-Matrix Composites, Proceedings of the 2nd International Conference on Composite Materials, April, 1978, Toronto, Canada (Metallurgical Society of AIME, Warrendale, Pa, 1978) pp. 175–188.

    Google Scholar 

  50. R. Thompson, S. Badzioch, R. H. Biddulph, G. K. Creffeld, J. B. Martin andA. J. Wickens,Powder Met. 19 (1976) 181.

    Google Scholar 

  51. S. Badzioch, R. H. Biddulph, G. K. Creffeld, J. B. Martin andA. J. Wickens,Composites 9 (1978) 278.

    Google Scholar 

  52. N. Igata andA. Kohyama, The Effect of Interface on the Mechanical Behaviour of Molybdenum Reinforced Metal Composites, Proceedings of the International Conference on Composite Materials, April, 1978, Toronto, Canada (Metallurigical Society of AIME, Warrendale, Pa, 1978).

    Google Scholar 

  53. H. Hassler andH. Schreiner,Int. J. Powder Met. and Powder Tech. 16 (1980) 21.

    Google Scholar 

  54. I. M. Pavlov, G. G. Leshkevich andM. M. Perkas, in “Plastic Working of Metals and Alloys” edited by N. A. Ageev (Izdatel'stvo Nauka, Moscow, 1979) pp. 49–58.

    Google Scholar 

  55. I. Shiota andO. Watanabe J. Mater. Sci. 14 (1979) 1121.

    Google Scholar 

  56. Idem, ibid. 14 (1979) 699.

    Google Scholar 

  57. Idem, J. Jap. Inst. Met. 39 (1975) 122.

    Google Scholar 

  58. Idem, ibid. 38 (1974) 788.

    Google Scholar 

  59. P. W. Jackson andJ. R. Marjoram,J. Mater. Sci. 5 (1970) 9.

    Google Scholar 

  60. I. Shiota andO. Watanabe,J. Jap. Inst. Met. 36 (1972) 760.

    Google Scholar 

  61. P. F. Thomason,J. Mech. Phys. Sol. 20 (1972) 152.

    Google Scholar 

  62. R. L. Pinckney andA. K. Dhingra, Design and Fabrication of High-Modulus Fibre Stabilised Magnesium Transmission Cases, Proceedings of the 4th Conference on Fibrous Composites in Structure Design, San Diego, California, 1978.

  63. J. L. Chermont andF. Osterstock,Powder Met. Int. 11 (1979) 106.

    Google Scholar 

  64. M. J. Turner andD. L. Grande, Study of Advanced Composite Structural Design Concepts for an Arrow Wing Supersonic Cruise Configuration, NASA Contr. Rep. 2825, 1978.

  65. J. A. Dicarlo andJ. E. Maisel, NASA Technical Memo 78837, 1978.

  66. Idem, NASA Technical Memo 79080, 1979.

  67. Idem, NASA Technical Memo 73882, 1978.

  68. D. R. Tenny, NASA Technical Note D-8299, 1976.

  69. J. A. Dicarlo, NASA Technical Memo X-71710, 1975.

  70. J. M. Kenndey, D. R. Tenny andC. T. Herekovich, Tensile and Compressive Stress-Strain Behaviour of Heat Treated Boron-Aluminium, Proceedings of the 2nd International Conference on Composite Materials, April, 1978, Toronto, Canada (Metallurgical Society of AIME, Warrendale, Pa, 1978).

    Google Scholar 

  71. C. T. Lynch andJ. P. Kershaw, “Metal Matrix Composites” (CRC Press, Boca Raton, Florida, 1972).

    Google Scholar 

  72. J. A. Dicarlo, Time-Temperature-Stress Dependence of Boron Fibre Deformation,Proc. ASTM STP-617, 1977, p. 443.

  73. L. O. K. Larsson, Thermal Stresses in Metal Matrix Composites, Proceedings of the International Conference on Composite Materials, April, 1978, Toronto, Canada (Metallurgical Society of AIME, Warrendale, Pa, 1978).

    Google Scholar 

  74. P. F. Thomason,Proc. Roy. Soc. Lond. A348 (1976) 265.

    Google Scholar 

  75. J. Awerbuch andH. T. Hahn,J. Comp. Mater. 13 (1979) 82.

    Google Scholar 

  76. Idem, ibid. 13 (1978) 222.

    Google Scholar 

  77. P. F. Thomason, The Development of Internal Stresses in Metal-Matrix Composites Under Cyclic Loading, Proceedings of the International Conference on Fracture Mechanics and Technology, March, 1977, Hong Kong.

  78. H. S. Morgan andR. M. Jones, Buckling of Rectangular Cross-Ply Laminated Plates with NonLinear Stress-Strain Behaviour, ASME Paper 78-PVP-64, 1978.

  79. B. Crossland andJ. D. Williams,Met. Rev. (No. 144).

  80. A. S. Bahrani andB. Crossland, Explosive Welding and Cladding: An Introductory Survey and Preliminary Results, Proceedings of the Institute of Mechanical Engineers (1964) p. 179.

  81. D. V. Wilson, W. T. Roberts, J. J. Moore, R. F. Stokes andJ. Farmer, Strong Composites Based on All-Metal Systems, Proceedings of the 15th International Machine Tool Development and Research Conference, Birmingham, 1974 (Macmillan, London, 1975) pp. 685–94.

    Google Scholar 

  82. G. Pickard andP. F. Rimer,Sheet Met. Ind. 51 (1974) 16.

    Google Scholar 

  83. M. A. Moore,Mater. Eng. Appl. 1 (1978) 97.

    Google Scholar 

  84. S. M. Etris (Ed.), ASTM Standardization News — Special Issue on Wear, September, 1974.

  85. Y. Yutori, S. Nomura andI. Kokubo,Sheet Met. Ind. Int. 56 (1979) 7.

    Google Scholar 

  86. J. Profit,ibid. 51 (1974) 44.

    Google Scholar 

  87. D. K. C. Anderson,ibid. 51 (1974) 36.

    Google Scholar 

  88. M. L. Booth,Chart. Mech. Eng. 23 (1976) 71.

    Google Scholar 

  89. C. Körner,Wt-Z. Int. Fertig. 69 (1979) 347.

    Google Scholar 

  90. R. S. Skinner,Materials 1 (1979) 11.

    Google Scholar 

  91. A. G. Herbert,Sheet Met. Ind. 57 (1980) 220.

    Google Scholar 

  92. Nippon Steel Corporation Report on “Porcelain Enameling Steel Sheets”, October, 1979.

  93. J. Wilson,Sheet Met. Ind. 51 (1974) 52.

    Google Scholar 

  94. M. Blankfield,ibid. 51 (1974) 32.

    Google Scholar 

  95. J. C. Gregory,Chart. Mech. Eng. 24 (1977) 41.

    Google Scholar 

  96. G. F. Bidmead,ibid. 26 (1979) 37.

    Google Scholar 

  97. M. B. Holland,ibid. 26 (1979) 43.

    Google Scholar 

  98. CME Data Sheet 7,Chart. Mech. Eng. 25 (1978) 77.

    Google Scholar 

  99. F. Ellis, A Preliminary Study of Methods of Deposition Forming, Proceedings of the 18th International Machine Tool Design and Research Conference, London, 1977 (Macmillan, London, 1978) pp. 203–8.

    Google Scholar 

  100. A. R. E. Singer,ibid. p. 209–16.

    Google Scholar 

  101. Idem, Met. Tech. 4 (1970) 209.

    Google Scholar 

  102. S. W. Bradsheet, Process of Coating and Hot Working of Metals, US Patent 28 69 227.

  103. K. G. Latimer, P. J. Read andT. D. W. Reynolds, The Structure and Mechanical Properties of Aluminium Alloys Produced in Bulk by a Metal Spraying Process, Institute of Metals Conference on Modern Metallurgy, September, 1973, Oxford.

    Google Scholar 

  104. A. R. E. Singer andS. E. Kisakurek,Met. Tech. 12 (1976) 565.

    Google Scholar 

  105. H. Shimizu, J. F. Dolowry, Jr,R. J. Taylor andB. A. Webb, Metal-Matrix Composites Behaviour and Aerospace Applications, Society of Automotive Engineers Paper 670861, 1967.

  106. J. Berok andK. R. Karasek, High Temperature Strength and Fracture Mode ofIn Situ Formed Cu-Nb Multifilamentary Composites, Proceedings of the Conference on New Developments and Applications in Composites, St. Louis, Montana, 1979.

  107. J. Bevk, J. P. Harbison andJ. L. Bell,J. Appl. Phys. 49 (1978) 6031.

    Google Scholar 

  108. C. C. Chamis, J. H. Sinclair andR. F. Lark, in “Dynamic Response of Damaged Angleplied Fibre Composites, Modern Development of Composite Materials and Structures”, edited by J. R. Vinson (ASME, New York, 1979).

    Google Scholar 

Download references

Author information

Authors and Affiliations

  1. Department of Engineering, University of Cambridge, Cambridge, UK

    W. Johnson & S. K. Ghosh

Authors
  1. W. Johnson
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. S. K. Ghosh
    View author publications

    You can also search for this author in PubMed Google Scholar

Rights and permissions

Reprints and permissions

About this article

Cite this article

Johnson, W., Ghosh, S.K. Some physical defects arising in composite material fabrication. J Mater Sci 16, 285–301 (1981). https://doi.org/10.1007/BF00738617

Download citation

  • Received:

  • Accepted:

  • Issue Date:

  • DOI: https://doi.org/10.1007/BF00738617

Keywords

Search

Navigation