**1. Introduction**

90 Woven Fabrics

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Composite material, also called composite, a solid material that results when two or more different substances, each with its own characteristics, are combined to create a new substance whose properties are superior to those of the original components in a specific application (Encyclopædia Britannica, 2011). Because the objective in manufacturing component is to produce a stiff and a strong material with a low density, these materials have found place in many application fields such as land transportation, marine, construction, aerospace and medical. There are two constituents in a composite material which are the reinforcement and matrix phases. From the matrix point of view, composites can be divided into three main categories; polymer, metal and ceramic matrix composites (Zhang, 2003). Based on the reinforcement mechanism, composites can be separated as particle reinforced (large particle, dispersion strengthened), fibre reinforced (continuous (aligned), and short fibres (aligned or random)) and structural composites (laminates, sandwich). Fibre reinforced composites have been first introduced in exterior parts of Corvette in 1953. Today, fibre reinforced composites are used in many application fields.

Textile structural composites usually consist of stacked layers known as 2D laminates, exhibit better in-plane strength and stiffness properties compared to those of metals and ceramics (Bilisik, 2010, 2011; Mohamed&Bogdanovich, 2009). However, the application of 2D laminates in some critical structures in aircraft and automobiles has also been restricted by their inferior impact damage resistance and low through thickness mechanical properties when compared against the traditional aerospace and automotive materials such as aluminium alloys and steel (Mouritz et al., 1999). These structures have low out-of plane properties because of the lack of third direction reinforcements which will result in low delamination resistances (Chou, 1992). In order to improve interlaminar properties of the 2D laminates, three dimensional (3D) textile preforms have been developed by using different manufacturing techniques like weaving, knitting, braiding, stitching, and non-woven manufacturing. Among these manufacturing techniques, sewing and 3D weaving are the promising technologies which address the shortcomings of the stack-reinforced composites (Padaki et al., 2010). Since manufacturing technology has a direct effect on the fibre orientation and fibre volume fraction of the preform, the properties of the end product will vary depending on the production and end-use requirements (Peters, 1998).

Although 3D woven preforms have been used for approximately forty years in different application fields, there is not a common understanding and definition of these fabrics

6. A non-woven, non-interlaced 3D fabric forming process designed to connect three orthogonal sets of yarns together with no interlacing (weaving), interloping (knitting), or intertwining (braiding). The fabric is held together by a special binding

However Soden and Hill added a new category as 4A to Khokar's classification for the fabrics that could be placed between categories 4 and 5 where the conventional 2D weaving process uses three sets of yarns to produce *an interlaced 3D fabric* with yarns in the warp,

Regardless of the types of machines used, weaving technology is capable of constructing 3D fabrics with many different geometrical shapes. Chen studied the configurations and geometries of the 3D woven fabrics and classified 3D woven fabrics into four different

> Compound structure, with regular or tapered geometry

Uneven surfaces, even surfaces, and tunnels on different level in multi-directions

Tubular nodes and solid nodes

Multilayer Spherical shells and open box shells

In 3D woven fabrics, generally multilayer, angle interlock and orthogonal weave architectures are the most widely used weave structures. While multilayer and angle interlock weave structures can be produced with conventional 2D weaving machines especially with shuttle looms, orthogonal weave architecture needs a special designed 3D weaving machine to be produced. Orthogonal weave structures consist of three sets of yarns that are perpendicular to each other (X, Y and Z coordinates). In this particular 3D woven fabric formation process, Z yarns interconnect all individual warp- and fill-directional yarns and thus solidify the fabric (Bogdanovich, 2007). Mechanical and structural properties of the composites having orthogonal weave architectures with various binding weaves and different numbers of layers were investigated (Chen&Zanini, 1997 as cited in

 Since straight yarns exist in the orthogonal structures, tensile stiffness and strength properties of these structures are well regardless of type of binding weave. However, tensile stiffness and strength values of these weave structures are directly proportional

weft and through-the-thickness directions (Soden&Hill, 1998).

Multilayer Orthogonal Angle Interlock

Multilayer Orthogonal Angle Interlock

Table 1. 3D textile structures and weave architectures (Chen, 2011).

Behera&Mishra, 2008). The results of the investigation are as follows:

Hollow Multilayer

Shell Single layer

**2.3 Weave structures and properties** 

with the number of layers.

categories, as listed in Table 1 (Chen, 2007 as cited in Chen et al., 2011).

**Structure Architecture Shape** 

process.

Solid

Nodal

which make them difficult to comprehend. Therefore, this chapter attempts to make a detailed overview of 3D woven fabrics, basic structure of 3D woven fabrics, definitions and classifications of 3D woven fabrics in comparison with 2D woven fabrics.
