Polymer matrix composites (PMCs) are composite materials that consist of a polymer matrix reinforced with fibers. The fibers are usually glass, carbon, or aramid, and they significantly improve the strength of the polymer. PMCs combine the corrosion resistance and inexpensive processing of polymers with the high strength and stiffness of fiber reinforcements. As a result, these materials have become extremely popular in aerospace, automotive, marine, and infrastructure applications where high strength to weight ratio is required. This article discusses the fundamentals of PMCs and explores their current and future applications.

What are PMCs?

PMCs consist of a continuous or discontinuous fiber reinforcement embedded within a polymer matrix. The matrix protects the fibers from damage and environmental degradation while transferring stress between fibers. Common polymer matrices used include thermosetting polymers like epoxy, polyester, phenol-formaldehyde and thermoplastics like polypropylene, polyethylene and nylon. Glass, carbon and aramid are the most widely used fiber reinforcements due to their high strength and stiffness characteristics.

The unique combination of properties in PMCs is attributed to the load sharing phenomenon between the fibers and matrix. Fibers carry most of the load acting along their direction keeping the material lightweight. The matrix keeps fibers in place and transfers stress between them, while also protecting them from damage. This results in materials possessing over 10 times higher strength than corresponding unreinforced polymers but with significantly lower density compared to traditional metals.

Fabrication and Characteristics

PMCs are typically manufactured using the layup and resin transfer molding processes. First, fiber reinforcements like woven fabrics or unidirectional tapes are cut and arranged in a mold cavity. A liquid thermosetting resin is then injected which wets and coats the fibers upon curing. PMCs can also be made by dispersing short fibers or nanoparticles in the polymer matrix followed by molding.

Key characteristics of PMCs include:

- High strength to weight ratio: Carbon fiber reinforced PMCs can be over 5 times stronger than aluminum but 45% lighter.

- Tailorable properties: Varying fiber type, orientation and weight fraction allows optimizing properties for different applications.

- Resistance to corrosion: Polymers provide corrosion resistance making PMCs suitable for marine applications.

- Low thermal conductivity: PMCs are preferred for applications requiring thermal insulation.

- Durability: Proper adhesion between fiber and matrix leads to durable and long-lasting materials.

- Mass producible: Sheet molding allows large scale production of complex parts at low costs.

Applications in Different Sectors

Aerospace: Carbon fiber reinforced Polymer Matrix Composites have revolutionized the aircraft industry by reducing weight. Up to 50% of the new Boeing 787 and Airbus A350 airframes are composed of composites. PMC wings, fuselages and empennages provide improved performance and reduce fuel consumption.

Automotive: Use of glass and carbon fiber reinforced PMCs has increased from almost 0% to over 20% in premium cars due to better strength, stiffness and reduced weight. Exterior body panels, driveshafts, brake calipers and engine covers are commonly made of composites. Weight savings directly improve fuel efficiency.

Marine: Reliability against corrosion makes PMC propellers, rudders and hulls ideal for ships and boats. Superior strength to weight allows designing larger, faster and more fuel efficient vessels. Carbon fiber PMC masts also provide stability and damage tolerance.

Sports equipment: High performance sporting goods utilize PMC's tailorable properties. Carbon/epoxy composites are used in racing bicycles, fishing rods, tennis rackets, golf clubs and protective sporting gear due to their lightweight and impact resistant designs.

Renewable Energy: Wind turbine blades over 60 meters in length are fabricated from epoxy bonded glass fiber composites. The weight savings allows using smaller, more cost-effective turbines. Carbon fiber composites are also gaining importance in hydrokinetic turbines installed in oceans and tidal streams.

Way Forward

As materials providing extreme strength and stiffness at low densities, polymer matrix composites are revolutionizing structural designs across industries. Continuous research towards lower manufacturing costs will further increase their application potential. Development of self-healing polymers extending damage tolerance and eco-friendly bio-based resins reducing reliance on petroleum products will ensure the sustainable growth of these materials. With their tailorable multi-functional properties, composites are undoubtedly the materials of the future that will transform next generation engineering systems.

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