5.4.6 · D5Materials Chemistry (Aerospace)
Question bank — Polymer-matrix composites — CFRP, GFRP; ply lay-up, laminate theory
True or false — justify
A single carbon/epoxy ply is stiff in every in-plane direction.
False — it is stiff only along the fibres (); across them the soft matrix sits in series and can be ~19× smaller, so off-axis it is limp.
The rule of mixtures gives the exact longitudinal modulus.
It is an upper bound (iso-strain, springs in parallel); real values sit slightly below because bonding and fibre misalignment are never perfect.
Making the lay-up balanced alone guarantees the panel will not warp.
False — balanced only kills tension–shear coupling; warping comes from a non-zero matrix, which needs symmetry to vanish. You need balanced and symmetric.
For a symmetric laminate the coupling matrix equals zero.
True — every ply at has a mirror twin at , and weights plies by -differences that cancel in pairs, so stretching and bending decouple.
Glass fibre (GFRP) is stiffer than carbon fibre (CFRP).
False — carbon has far higher (~230 GPa vs ~70 GPa); glass wins on cost and toughness, not stiffness.
In bending, a ply at the mid-plane contributes as much stiffness as one at the surface.
False — bending stiffness weights plies by , so an outer ply (large ) dominates; a mid-plane ply barely helps resist bending.
A higher fibre volume fraction always makes a stronger composite.
False — above ~65–70% there is too little matrix to wet all fibres, so voids form and load transfer collapses; optimum is ~0.55–0.65.
The matrix carries most of the load in a longitudinally-pulled ply.
False — the stiff fibres carry the bulk; the matrix mainly holds fibres straight, spreads load between them, and resists shear/compression.
A quasi-isotropic laminate behaves exactly like an isotropic metal in all respects.
Only its in-plane stiffness is direction-independent; through-thickness properties, strength, and fatigue behaviour stay anisotropic.
Spot the error
"Transverse loading is iso-strain, so use ."
Transverse loading is iso-stress (fibre and matrix in series); use the inverse rule , which gives a much smaller .
" means the panel is stronger because it couples two behaviours."
A non-zero is a defect of design, not a bonus — it makes the panel warp under load or temperature; we deliberately zero it with symmetry.
"Put the stiffest plies at the mid-plane to maximise bending stiffness."
Backwards — because , stiff plies belong near the surfaces where (and strain ) is largest.
"CFRP beats aluminium because carbon fibre is stronger than steel in absolute terms."
The real win is specific strength/stiffness (per kilogram); low density is what matters in flight, not raw absolute strength — see Specific strength and stiffness in aerospace materials.
"Because both bounds average the phases, and come out about the same."
They differ enormously (~19×) — parallel (add) versus series (add reciprocals) are very different averages, which is exactly why plies are anisotropic.
" is symmetric, so it won't warp."
is not symmetric — mirrored it would read ; the plain two-ply stack has non-zero and warps.
Why questions
Why do we bother stacking plies at different angles instead of using one thick unidirectional ply?
One ply is strong only along its fibres; rotating plies () shares strength across every loading direction we need — see Anisotropy and crystal directions.
Why is a loose bundle of fibres, with no matrix, useless as a structural material?
Bare fibres buckle in compression, can't carry shear, and one break isn't shared to neighbours; the matrix transfers load and gives integrity — see Fibre–matrix interface and load transfer.
Why does the matrix ignore where each ply sits, while cares a lot?
weights plies by thickness (), which is position-independent; weights by , so stacking order changes bending stiffness dramatically.
Why is epoxy (a thermoset) chosen over a typical thermoplastic for many aerospace matrices?
Its cross-linked network gives high stiffness, creep resistance and thermal stability under load, at the cost of reprocessability — contrast in Thermoset vs thermoplastic polymers.
Why does a balanced lay-up remove tension–shear coupling?
Each ply's shear response is the mirror-opposite of its partner, so their off-diagonal () contributions cancel and pure tension gives pure stretch.
Why is the harmonic (inverse) rule a lower bound on modulus?
In series the softest phase dominates the total displacement, so the combined modulus is dragged down toward the matrix value — the weakest link governs.
Edge cases
If (all matrix), what does predict?
It reduces to — pure matrix modulus, correctly recovering the resin-only limit.
If (all fibre), what does the transverse rule give for ?
, so — but this is unphysical because you cannot pack fibres with zero matrix and still bond them.
What happens to the load-transfer if a single fibre snaps mid-length inside a good matrix?
The matrix shears load back into the broken fibre over a short distance and to neighbours, so the part survives — one break is not catastrophic, unlike a bare bundle.
For a perfectly quasi-isotropic laminate, does off-axis loading still cause tension–shear coupling?
No in-plane coupling if it is also balanced and symmetric — the evenly spread angles make isotropic-like and , so any in-plane direction behaves the same.
What is the limiting behaviour of the anisotropy ratio as grows?
It grows too — stiffer fibres in a soft matrix widen the gap, making a single ply ever more direction-dependent and the lay-up strategy ever more essential.
At the exact mid-plane (), what is a ply's contribution to the (bending) matrix?
Essentially zero — its weight vanishes at , so mid-plane plies do almost nothing for bending resistance.