MSE 04 Synthesis and Mechanical Testing of Composite Materials Reinforced with Carbon Fiber

This experiment creates and tests composite materials reinforced with carbon fiber to evaluate their strength, durability, and flexibility compared to traditional materials.

Materials & Processes: Composites fibers and resins | CompositesWorld (Composites World)

Introduction

Composite materials are materials that are composed of two or more distinct materials with different physical and chemical properties, which are bound together to form a superior material with enhanced mechanical properties such as strength, durability, and flexibility. This type of material is used in a wide variety of different industries due to its higher strength-to-weight ratio and superior mechanical performance. By combining a matrix material (a constituent of a composite material, such as epoxy resin or glue) with reinforcement materials (such as carbon fiber, fiberglass, or natural fibers), the new composite material produced will exhibit improved tensile strength, overall durability, as well as flexibility.

Composite materials are essential in everyday life as they provide solutions for areas where traditional materials, such as metal or concrete, fall short. They can be readily adaptable and altered to best suit the requirements of certain tasks, and they possess unique properties, such as impact resistance and lightweight durability, that are not commonly found in more traditional materials.

The purpose of this investigation is to produce and examine, and evaluate the

mechanical properties of a lab-made composite material.

High-Performance Nanoscale Metallic Multilayer Composites: Techniques, Mechanical Properties and Applications (Materials)

Aim

This experiment aims to synthesize and test composite materials reinforced with carbon fiber and to determine their benefits over other conventional materials.

Context

When traditional materials do not sufficiently possess the required properties for certain tasks, composite materials can offer a quick and cost-effective solution to this problem. Nowadays, composite materials are widely used for their ability to combine and take the best of both worlds when it comes to the desirable properties of different materials, unlike traditional materials, which may have certain limitations when it comes to strength or flexibility. In everyday life, where there can be a plethora of different materials to choose from, each has distinct pros and cons when it comes to the properties it possesses. Composite materials are able to be crafted and fine-tuned to perfection and are more often than not the best possible choice of material for many tasks. This experiment will provide insight into how the binding of a reinforcement material with a matrix material can influence the strength and flexibility of composites.

Theory

Composite materials consist of two main components:

1. Matrix: A binding substance that holds and fixes the reinforcement material in place and can transfer stress between layers. Examples of matrices include epoxy resin and glue.

2. Reinforcement – A reinforcement material provides the strength and stiffness in composites and is the backbone of the material. A few examples of reinforcement materials include carbon fibre, fiberglass, and other natural fibers such as paper

The strength, durability, and lightweight flexibility of a composite material mainly depend on the following factors:

• The number of layers in the composite

• The type of reinforcement material used

• The bonding strength between the matrix and the reinforcement material.

When tensile load is applied to a composite material, the reinforcement material bears the majority of the load, whilst the matrix can distribute the stress. Although when a load large enough is applied, the structure or a composite material is still able to fail, resulting in the deformation of the composite or cracks appearing in the matrix.

Composites (The Essential Chemical Industry)

Materials

1. Base materials:

   • Epoxy resin and hardener (available at hardware stores or online)

   • Alternative binder: Wood glue or white glue (if epoxy isn’t available)

2. Reinforcement materials:

   • Fiberglass fabric, carbon fiber fabric, or natural fibers (like jute or paper)

   • Thin plastic sheets, paper strips, or fabric scraps (for simpler composites)

3. Mold:

   • A flat mold or tray (e.g., baking sheet, plastic container)

4. Release agent:

   • Petroleum jelly or wax paper to prevent sticking.

5. Mixing tools:

   • Disposable cups, sticks for stirring, and gloves for handling resin.

6. Weights:

   • A stack of books, water bottles, or a load-testing device.

7. Measuring tools:

   • Ruler, caliper, or scale.

8. Optional testing equipment:

   • Clamp or tensile testing rig (if available).

   
   
   
   
   
   

Procedure

Step 1: Prepare the Mold

1. Line the Mold:

   • Apply a release agent (petroleum jelly or wax paper) to the mold to prevent the composite from sticking.

2. Cut Reinforcement Material:

   • Cut the reinforcement material (e.g., fiberglass, fabric) into layers that fit the mold dimensions.

   
   
   
   

Step 2: Mix the Matrix Material

1. Prepare the Resin:

   • Mix the epoxy resin and hardener according to the manufacturer’s instructions (usually 2:1 ratio). Stir thoroughly for 2–3 minutes to ensure proper curing.

2. Alternative:

   • If using glue, dilute slightly with water to make it easier to spread.

   
   
   
   

Step 3: Create the Composite Material

1. Layering:

   • Place one layer of reinforcement material (e.g., fiberglass) in the mold.

   • Pour a thin layer of resin or glue over it and spread evenly with a stick or brush.

   • Repeat this process, alternating layers of reinforcement and resin, until you have 3–5 layers.

2. Compression:

   • Press the layers firmly with a flat object to remove air bubbles and ensure even bonding between layers.

   
   
   
   

Step 4: Cure the Composite

1. Set the Composite:

   • Leave the composite in the mold for the recommended curing time (usually 24 hours for epoxy resin, faster for glue).

2. Remove from Mold:

   • Once fully cured, carefully remove the composite material.

   
   

Step 5: Strength Testing

1. Cut Samples:

   • Cut the composite into uniform rectangular strips (e.g., 10 cm × 2 cm).

2. Set Up Testing Area:

   • Place the composite strip between two supports (e.g., bricks) with a gap in the middle.

3. Apply Weight:

   • Gradually add weights to the center of the strip until it bends or breaks.

4. Record Data:

   • Note the maximum weight the strip holds before failure. Measure any deformation using a ruler or caliper.

5. Optional Tensile Test:

   • If using a clamp or tensile testing rig, secure both ends of the sample and pull until the material fails. Record the force applied.

   
   
   
   

Observations

1. Strength:

   • Compare the maximum load each composite sample can bear.

2. Flexibility:

   • Observe how much the material bends before breaking.

3. Failure Mode:

   • Examine whether failure occurs due to delamination, fiber breakage, or matrix cracking.

   
   

Analysis

1. Effect of Layers:

   • Test composites with different numbers of layers (e.g., 3 vs. 5) to see how strength increases.

2. Reinforcement Materials:

   • Compare the performance of different reinforcement materials (e.g., fiberglass vs. jute).

3. Matrix Variation:

   • Test different resins or binders to observe how the matrix affects strength.

   
   

Applications

• Learn how composites are designed and tested for use in aerospace, automotive, and construction industries.

• Explore eco-friendly alternatives by using natural fibers and bio-resins.

Figure 1.1 Carbon Fiber-enhanced Composite Material Synthesis

Qualities of composite materials

• Improved mechanical properties: The use of reinforcement materials significantly increases strength compared to pure materials

• Customization: By combining multiple layers of matrix and reinforcements, the material can be adjusted to meet the necessary mechanical requirements for certain tasks

• Durability: Composite materials exhibit improved durability and resistance to deformation compared to unreinforced materials.

Example 5: Composite material | Applications | SunForce | Foam products | Asahi Kasei Corporation (Asahi Kasei Corporation)

Economic and Environmental Factors

• Whilst the initial cost to produce and use composite materials may be higher than traditional materials, the long-term cost reductions due to not needing to be repaired and replaced quite as often can lead to savings over the long term.

• Epoxy-based resins are often more expensive than glue-based ones; however, they can provide superior strength and distribution of stress.

• Natural fibers tend to be cheaper than synthetic fibers and are a more

  sustainable alternative, but comes with trade-offs such as reduced tensile

  strength.

• These materials aren’t easily able to be reused or recycled, which may lead to an increase in pollution in the environment.

The Advantages of Wood Plastic Composite in Construction (CIDB Malaysia)

Chemical Properties and Structure

• Matrix composition: Epoxy resin is a polymer that cures and dries to become a rigid structure when mixed with a hardener, which forms a strong adhesive bond between each layer and the reinforcement material

• Reinforcement material: Reinforcement materials such as fiberglass and carbon fibers consist of long polymer chains that increase tensile strength.

• Whilst composite materials may be able to withstand higher tensile loads, some composite materials do not have high impact resistance, making deformations a liability under high-stress environments.

Properties of multifunctional composite materials based on nanomaterials: a review - RSC Advances (The Royal Society of Chemistry)

In many ways, composite materials can be compared to interstitial alloys, a topic often introduced in high school chemistry. Interstitial alloys are formed when small atoms, such as carbon, fit into the spaces (interstices) between larger metal atoms in a lattice, enhancing strength and hardness. Similarly, composites improve material performance by combining a matrix with reinforcement, where the reinforcement fills “gaps” in mechanical performance that the matrix alone cannot provide. Both systems demonstrate how altering structure at the microscopic level leads to macroscopic improvements in strength, durability, and flexibility, making the comparison an accessible way for students to understand the role of structure–property relationships in materials science.

Interstitial Alloys - AP Chemistry Study Guide (Save My Exams)

Conclusion

Composite materials are essential in a diverse variety of industries in this day and

age. A combination of its enhanced mechanical properties and low cost, this

material is vital for many applications. With additional development, sustainable

composite materials can provide eco-friendly alternatives in various industries.

Bibliography Citations

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Omar Shabbir Ahmed, Aabid, A., Ali, M., Meftah Hrairi, & Norfazrina Mohd Yatim. (2023). Progresses and Challenges of Composite Laminates in Thin-Walled Structures: A Systematic Review. ACS Omega, 8(34), 30824–30837. https://doi.org/10.1021/acsomega.3c03695

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