Types of Composite Matrix Materials and Their Applications

By Taha KhanReviewed by Lexie CornerDec 10 2024

Image Credit: asharkyu/Shutterstock.com

This article explores the types of composite matrix materials, their properties, and their applications across various industries.

Polymer Matrix Composites

Polymer matrix composites (PMCs) are made by reinforcing a polymer-based matrix with glass, carbon, or aramid fibers. PMCs are classified into thermosetting and thermoplastic resins based on the type of polymer used, with each category offering distinct properties.

Thermosetting resins, such as epoxy and polyester, harden through a chemical curing process that forms an irreversible, rigid structure. This gives these PMCs a high strength-to-weight ratio, chemical resistance, and long-term durability. In contrast, thermoplastic resins like nylon and polypropylene can be reheated and reshaped, making them ideal for applications requiring toughness, impact resistance, and recyclability.¹

PMCs have a wide range of applications across various industrial sectors. The automotive industry uses body panels, bumpers, and other structural components to reduce vehicle weight and improve fuel efficiency.

In aerospace, PMCs are essential in aircraft design, with some advanced military aircraft incorporating up to 70 wt.% PMCs to enhance durability and reduce weight. Additionally, PMCs are used to improve performance and endurance in sports equipment such as tennis rackets, vaulting poles, skis, golf club shafts, and bicycles.¹

Metal Matrix Composites

Metal matrix composites (MMCs) consist of a metallic matrix, such as aluminum, magnesium, or titanium, reinforced with materials like silicon carbide, boron, or carbon fibers. These composites offer higher strength and thermal stability than polymer-based composites, and their properties can be tailored for specific applications.

For example, aluminum-based MMCs are often reinforced with silicon carbide to improve wear resistance and mechanical properties. Magnesium-based MMCs are ultra-lightweight, whereas titanium-based MMCs provide strength and resistance to high temperatures.²

MMCs are particularly important in aerospace and defense applications. They are used in rotary components and heat exchangers, where high mechanical strength and thermal stability are essential.

Aluminum-based MMCs (Al-MMCs) are commonly used in structural applications within the defense sector. Titanium matrix composites (TMCs), on the other hand, are ideal for high-temperature jet engine components due to their excellent corrosion resistance and ability to withstand temperature reactions. Additionally, TMCs can reduce weight by 50 % compared to steel or nickel-based superalloys in jet propulsion systems, making them crucial for advanced aircraft engines, frames, and space shuttle components.²

Ceramic Matrix Composites

Ceramic matrix composites (CMCs) are made from ceramic matrices, such as silicon carbide or aluminum oxide, and are reinforced with fibers of similar materials or carbon. These materials are designed to maintain structural integrity under extreme temperatures and in corrosive environments.

For instance, silicon carbide-based composites are known for their high thermal conductivity and fracture toughness, achieved through the reinforcement of carbon or ceramic fibers. Aluminum oxide composites, reinforced with ceramic whiskers or fibers, provide wear resistance and electrical insulation for specialized applications.

A key application of CMCs is in the aerospace sector, where they are used in exhaust nozzles due to their ability to withstand extreme heat. CMCs are also used in nose masks, leading edges of wings, heat shields, turbine engines, and nuclear reactors, where they serve as structural materials, enduring intense heat and radiation without degrading.³ In the automotive industry, high-performance brake discs and clutches rely on the thermal stability and strength of CMCs.

Carbon Matrix Composites

Carbon matrix composites, also known as carbon-carbon (C/C) composites, are made by embedding carbon fibers within a carbon matrix. These composites can be categorized based on their reinforcement types and manufacturing processes.

For instance, unidirectional composites have carbon fibers aligned in a single direction within the carbon matrix, offering maximum strength and stiffness along the fiber direction. In contrast, woven or fabric composites are created by weaving carbon fibers into a fabric before embedding them in the matrix, resulting in multi-directional strength. ^{4, 5}

C/C composites can also be classified by manufacturing process. For example, composites made by Chemical Vapor Infiltration (CVI) or Liquid Impregnation with Pyrolysis have distinct characteristics.

CVI involves a gas-phase process where carbon-containing gases decompose and deposit carbon within the fiber matrix, producing composites with high thermal stability and low porosity. In contrast, the liquid impregnation process uses a carbon-rich resin to coat fibers, followed by pyrolysis to form the carbon matrix. While this method is more cost-effective, it typically results in composites with higher porosity compared to CVI.^{4, 5}

Carbon matrix composites are also important in the aerospace and defense industries. They are used in spacecraft components, including thermal protection systems and rocket nozzles, where their ability to withstand extreme conditions is critical. In defense, missile nose cones and heat shields benefit from the material’s lightweight and heat-resistant properties.

C/C composites are also found in high-end sports equipment, such as racing bicycles and tennis rackets, where their durability and low weight enhance performance.^4-6

Natural Fiber-Reinforced Composites

Another important type of composite matrix material is natural fiber-reinforced composites (NFRCs). As the world shifts towards more environmentally friendly materials, NFRCs align with the growing demand for green manufacturing by reducing reliance on fossil fuels and promoting the use of renewable resources. NFRCs are made by embedding natural fibers such as jute, flax, hemp, or sisal into polymer matrices.⁷

NFRCs are used in automotive interiors, construction materials, and packaging as a sustainable alternative to traditional composites. For instance, they are employed in door panels, dashboards, and insulation materials in vehicles due to their sound-absorbing properties and reduced environmental impact.⁷

The Future of Advanced Composites

Emerging research is focused on developing advanced composites with improved performance, including nano-engineered reinforcements, smart materials with self-healing capabilities, and increased use of natural fiber-reinforced composites. Industries are exploring composites that offer better strength-to-weight ratios, thermal stability, and environmental sustainability.

These composite materials have the potential to offer practical solutions for a range of engineering challenges, especially as manufacturers work to meet modern performance standards while reducing environmental impact.

How Can Composites Make Construction More Sustainable?

References and Further Reading

1. Kessler, MR. (2012). Polymer matrix composites: A perspective for a special issue of polymer reviews. Polymer Reviews. https://doi.org/10.1080/15583724.2012.708004
2. Srinivasan, V., Kunjiappan, S., Palanisamy, P. (2021). A brief review of carbon nanotube reinforced metal matrix composites for aerospace and defense applications. International nano letters. https://doi.org/10.1007/s40089-021-00328-y
3. Wang, X., Gao, X., Zhang, Z., Cheng, L., Ma, H., Yang, W. (2021). Advances in modifications and high-temperature applications of silicon carbide ceramic matrix composites in aerospace: a focused review. Journal of the European Ceramic Society. https://doi.org/10.1016/j.jeurceramsoc.2021.03.051
4. Rajak, DK., Pagar, DD., Kumar, R., Pruncu, CI. (2019). Recent progress of reinforcement materials: a comprehensive overview of composite materials. Journal of Materials Research and Technology. https://doi.org/10.1016/j.jmrt.2019.09.068
5. Yang, JY., Park, JH., Kuk, YS., Kim, BS., Seo, MK. (2020). One-step densification of carbon/carbon composites impregnated with pyrolysis fuel oil-derived mesophase binder pitches. https://doi.org/10.3390/c6010005
6. Agarwal, N., et al. (2024). An overview of carbon-carbon composite materials and their applications. Frontiers in Materials. https://doi.org/10.3389/fmats.2024.1374034
7. Kumar, S., Manna, A., Dang, R. (2022). A review on applications of natural Fiber-Reinforced composites (NFRCs). Materials Today: Proceedings. https://doi.org/10.1016/j.matpr.2021.09.131

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