The most common methods for preparing polymeric composites for microscopic analysis can be used for most fiber-reinforced composite materials. There are, however, a few composite materials that require special preparation techniques. This chapter discusses the processes involved in the preparation of titanium honeycomb composites, boron fiber composites, titanium/polymeric composite hybrids, and uncured prepreg materials.

Composite systems for cryogenic applications are discussed in this chapter. This chapter emphasizes filamentary-reinforced composites because they are the most widely used composite materials. It begins with a discussion on the approach to designing and fabricating with low-pressure laminate composites. This is followed by a section providing an overview of the materials in modern cryogenic technology. Then, the chapter describes the effect of cryogenic temperatures on materials properties; it also introduces the various joining techniques developed for composite materials. The effects of radiation on the properties of the materials are covered as well as the processes involved in testing laminates at cryogenic temperatures. Finally, the chapter provides information available on concrete aggregate composites.

This chapter discusses the properties and uses of fiber-reinforced composites. It also describes the effect of volume fraction and fiber length.

This chapter discusses the ambient-temperature corrosion characteristics of aluminum metal-matrix composites (MMCs), including composites formed with boron, graphite, silicon carbide, aluminum oxide, and mica. It also discusses the effect of stress-corrosion cracking on graphite-aluminum composites and the use of protective coatings and design criteria for corrosion prevention.

This chapter discusses the advantages and disadvantages of metal matrix composites and the methods used to produce them. It begins with a review of the composition and properties of aluminum matrix composites. It then describes discontinuous composite processing methods, including stir and slurry casting, liquid metal infiltration, spray deposition, powder metallurgy, extrusion, hot rolling, and forging. The chapter also provides information on continuous-fiber aluminum and titanium composites as well as particle-reinforced titanium and fiber metal (glass aluminum) laminates.

Metal-matrix composites can operate at higher temperatures than their base metal counterparts and, unlike polymer-matrix composites, are nonflammable, do not outgas in a vacuum, and resist attack by solvents and fuels. They can also be tailored to provide greater strength and stiffness, among other properties, in preferred directions and locations. This chapter discusses the processes and procedures used in the production of fiber-reinforced aluminum and titanium metal-matrix composites. It explains how the length and orientation of reinforcing fibers affect the properties and processing characteristics of both aluminum and titanium composites. It also provides information on fiber-metal laminates and the use of different matrix metals and reinforcing materials.

Metal-matrix composites (MMCs) work at higher temperatures than their base metal counterparts and can be engineered for improved strength, stiffness, thermal conductivity, abrasion and/or creep resistance, and dimensional stability. This chapter examines the properties, compositions, and performance-cost tradeoffs of common MMCs, including aluminum-matrix composites, titanium-matrix composites, and fiber-metal laminates. It also explains how fiber-reinforced composites and laminates are made, describing both continuous and discontinuous fiber matrix production processes.

This chapter discusses the types of fibers and matrix materials used in ceramic matrix composites and the role of interfacial coatings. It describes the methods used to produce ceramic composites, including powder processing, slurry infiltration and consolidation, polymer infiltration and pyrolysis, chemical vapor infiltration, directed metal oxidation, and liquid silicon infiltration.

This chapter provides a general description of materials and methods for manufacturing high-performance composites. The materials covered are polymer matrices and prepreg materials and the methods include infusion processes, composite-toughening methods, matrix-toughening methods, and dispersed-phase toughening. In addition, the chapter provides information on interlayer-toughened composites and honeycomb or foam structure composite materials. It also discusses the processes in optical microscopy of composite materials.

Ceramic-matrix composites possess many of the desirable qualities of monolithic ceramics, but are much tougher because of the reinforcements. This chapter explains how reinforcements are used in ceramic-matrix composites and how they alter energy-dissipating mechanisms and load-carrying behaviors. It compares the stress-strain curves for monolithic ceramics and ceramic-matrix composites, noting improvements afforded by the addition of reinforcements. It then goes on to discuss the key attributes, properties, and applications of discontinuously reinforced ceramic composites, continuous fiber ceramic composites, and carbon-carbon composites. It also describes a number of ceramic-matrix composite processing methods, including cold pressing and sintering, hot pressing, reaction bonding, directed metal oxidation, and liquid, vapor, and polymer infiltration.

This chapter discusses the failure mechanisms associated with fiber-reinforced composites. It begins with a review of fiber-matrix systems and the stress-strain response of unidirectional lamina and both notched and unnotched composite laminate specimens. It then explains how cyclic loading can lead to delamination, the primary failure mode of most composites, and describes some of the methods that have been developed to improve delamination resistance, assess damage tolerance, determine residual strength, and predict failure modes.

This chapter discusses the properties and processing characteristics of glass, aramid, carbon, and ultra-high molecular weight polyethylene fibers and related product forms, including woven fabrics, prepreg, and reinforced mats. It also includes a review of fiber terminology as well as physical and mechanical property data for commercially important high-strength fibers.

This chapter discusses design and certification considerations, including materials and process selection, the building block approach to certification, design allowables, and design guidelines. It also includes information on damage tolerance and environmental sensitivity.