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UNIVERSITY
MECHATRONICS AND ROBOTICS UNDERGRADUATE
STUDIES PROGRAM
MATERIALS SCIENCE AND ENGINEERING
UNDER SUPERVISION : PROF. IBRAHIM HASAB-ALLAH
METAL-MATRIX
COMPOSITES
MMCs
NOVEMBER, 2018
Contents
LIST OF FIGURES _______________________________________________________________ 1
ABSTRACT ____________________________________________________________________ 2
1. Introduction ________________________________________________________________ 2
2. Composites _________________________________________________________________ 2
2.1. Classification of Composite Materials _________________________________________ 3
2.1.1. On the Basis of Matrix Material __________________________________________ 3
2.1.2. On the Basis of Filler Material ___________________________________________ 4
3. Metal Matrix Composites (MMCs) _______________________________________________ 6
3.1. Properties of Metal-Matrix Composites _______________________________________ 7
3.2. Manufacturing and Forming Processes of MMCs ________________________________ 7
3.2.1. Solid-State Process ____________________________________________________ 7
3.2.2. Liquid State Processes _________________________________________________ 9
3.2.3. Semi-Solid State Processes _____________________________________________ 14
3.3 Mechanical and Microstructural Properties of Light MMCs _______________________ 15
3.4. The Most Common MMCs Systems _________________________________________ 15
3.5. Aluminum-Matrix Composites _____________________________________________ 16
3.5.1. Types of AMCs ______________________________________________________ 16
References __________________________________________________________________ 19
LIST OF FIGURES
Figure 1 The General Composition of Composites _____________________________________________ 3
Figure 2 Matrix Materials Classification _____________________________________________________ 4
Figure 3 Reinforcement Classification _______________________________________________________ 5
Figure 4 Mechanical Alloying Process Technique: Milling Action on the Powders ____________________ 9
Figure 5 Stir Casting ____________________________________________________________________ 10
Figure 6 Squeeze Casting ________________________________________________________________ 14
Figure 7 Microstructure of Types of AMCs __________________________________________________ 18
ABSTRACT
Metal matrix composites have been widely used. They have reached the degree of
maturity that indicates the expansion of their use. They possess many significantly properties
that dominate over the conventional monolithic metals including high specific strength:
specific modulus, damping capacity and high wear resistance. The report discusses the
composites with a general brief about their properties and the metal-matrix composites in
detail. It contains the metal matrix properties, their processing, the most-widely used
composites and their applications in industry. The information in the report was collected
from the online websites, research papers and articles and journals on the Internet. While
metal matrix composites have been obviously used in aircraft and aerospace industries -
heavy industries, in particular -their properties are still being researched for further
development and applications.
1. Introduction
Conventional monolithic materials have limitations in achieving good combination
of strength, stiffness, toughness and density. To overcome these shortcomings and to meet
the ever increasing demand of modern day technology, composites are most promising
materials of recent interest. Metal matrix composites (MMCs) possess significantly improved
properties including high specific strength; specific modulus, damping capacity and good
wear resistance compared to unreinforced alloys.
2. Composites
1
MMCs: Metal-Matrix Composites
elevated temperatures, an additional consideration is the difference in melting temperatures
between the matrix and the reinforcements. A large melting temperature difference may result
in matrix creep while the reinforcements remain elastic, even at temperatures approaching the
matrix melting point. However, creep in both the matrix and reinforcement must be considered
when there is a small melting point difference in the composite.
3.1. Properties of Metal-Matrix Composites
Compared to monolithic metals, MMCs have higher strength-to-density ratios, higher
stiffness-to-density ratios, better fatigue resistance, better elevated temperature properties,
higher strength, lower creep rate, lower coefficients of thermal expansion, better wear
resistance. The advantages of MMCs over polymer matrix composites higher temperature
capability, fire resistance, higher transverse stiffness and strength, no moisture absorption,
higher electrical and thermal conductivities, better radiation resistance, no out gassing, fabric
ability of whisker and particulate-reinforced MMCs with conventional metalworking
equipment. Some of the disadvantages of MMCs compared to monolithic metals and polymer
matrix composites are higher cost of some material systems, relatively immature technology,
complex fabrication methods for fiber-reinforced systems (except for casting), limited service
experience.
3.2. Manufacturing and Forming Processes of MMCs
MMC manufacturing can be broken into three types—solid, liquid, and vapor. Solid
state methods include powder blending and consolidation (powdered metal and discontinuous
reinforcement are mixed and then bonded through a process of compaction, degassing, and
thermo-mechanical treatment) and foil diffusion bonding (layers of metal foil are sandwiched
with long fibers, and then pressed through to form a matrix). Liquid state methods include
electroplating and electroforming(a solution containing metal ions loaded with reinforcing
particles is co-deposited forming a composite material), stir casting (discontinuous
reinforcement is stirred into molten metal, which is allowed to solidify), pressure infiltration(
molten metal is infiltrated into the reinforcement through use a kind of pressure such as gas
pressure), squeeze casting (molten metal is injected into a form with fibers pre-placed inside
it), spray deposition(molten metal is sprayed onto a continuous fiber substrate), reactive
processing ( a chemical reaction occurs, with one of the reactants forming the matrix and the
other the reinforcement). Semi-solid state methods include semi-solid powder
processing(powder mixture is heated up to semi-solid state and pressure is applied to form the
composites). Vapor deposition include physical vapor deposition (The fiber is passed through
a thick cloud of vaporized metal, coating it).
3.2.1. Solid-State Process
Solid state processes involve production of materials in solid state form (such as
powders in PM2. The first step in PM method is the blending/mixing of metal matrix and
2
PM: Powder Metallurgy
reinforcement powder, which is conducted using a ball-milling machine (without milling
media, e.g., steel balls). In some cases, reactive mixing is employed, in which reinforcement
particles and/or the alloying/catalyst element are milled together (with a milling media at
selected rpm and time duration). This step is undertaken so as to improve the wettability. The
powders so blended are then compacted usually by cold pressing (called “green compacts”),
and in some cases by using hot/vacuum hot pressing. The green compacts are then further
sintered using either of the methods of direct sintering using resistance furnace, microwave-
assisted sintering, spark plasma sintering, hot extrusion, severe plastic deformation, etc.
3.2.1.a. Mechanical Alloying
In the traditional PM process, the aim of blending is simply to mix the powders without
inducing material transfer between the mixed components. It is possible, however, to perform
a high energy mixing through milling media, so as to eliminate the voids between the matrix
and the reinforcement powders through a solid state bonding. For example, in mechanical
alloying (MA), matrix and reinforcement are alloyed together by inducing cold welding,
fracturing, and re-welding of the powder particles. The strengthening of metallic alloys is
achieved through grain size refinement and dispersion of particles. During the process, a small
quantity of the base powder is loaded into a sealed container, together with the grinding media,
then blended through agitation at high speed for a predetermined amount of time. As the kinetic
energy of the grinding balls depends on their mass and velocity, dense materials such as
stainless steel or tungsten carbide are preferred to ceramic. Main process parameters,
influencing the quality of the composite, comprise ball-to-powder ratio (BPR), time and
rotational speed of milling. After being
milled, powders are compacted, degassed, and consolidated. A process control agent
(PCA, usually referred to as lubricant or surfactant) is usually added while blending the
powders, aimed to minimize the effect of cold welding and consequent formation of large
powder clusters. Methanol, stearic acid, and paraffin compounds are used for this purpose.
During continuous severe plastic deformation, refinement of the internal structure of the
powders to the fine scales may occur, resulting in the production of nanostructured powders.
In the entire process, contamination of the powders must be carefully controlled. Possible
sources of contamination are the milling tools, milling atmosphere, as well as the PCA. During
consolidation, impurities may influence microstructural evolution and grain growth, leading to
a possible decrease of mechanical properties of the resulting composite. In some cases, the
milled powders obtained from mechanical alloying are also employed as reinforcing particles
for casting processes.
3.2.2. Liquid State Processes
Liquid-state processing routes are attractive as they are relatively simple, cost-effective,
and are potentially scalable to industrial level. These routes include stir casting, ultrasonic-
assisted casting, centrifugal casting, infiltration techniques, and disintegrated melt deposition
(DMD) method. Infiltration Process: Liquid metal alloy is infiltrated into the porous forms of
fibers/whiskers reinforcements. The volume fraction of the reinforcements usually ranges from
10-70%, depending on the level of porosity. Silica and metal-based mixtures are often
employed as binder to retain the integrity and shape of the porous forms.Spray Deposition:
Figure 4 Mechanical Alloying Process Technique: Milling Action on the Powders
Particle/whisker/short fiber reinforcements are injected into the spray, creating a deposition
layer of porosity of 5-10% on the metal surface. The depositions are then consolidated to full
density by further processing. For continuous (long) fiber reinforced metal matrix composites,
matrix metals are sprayed onto the fibers. The fiber spacing and fiber layer in this processing
method impact the fiber volume fraction and distribution.
3.2.2.a. Stir Casting
Liquid state fabrication of MMCs involves incorporation of dispersed phase into a
molten matrix metal, followed by its Solidification. In order to provide high level of
mechanical properties of the composite, good interfacial bonding (wetting) between the
dispersed phase and the liquid matrix should be obtained. Wetting improvement may be
achieved by coating the dispersed phase particles (fibers). Proper coating not only reduces
interfacial energy, but also prevents chemical interaction between the dispersed phase and the
matrix. The simplest and the most cost effective method of liquid state fabrication is Stir
Casting.
Stir Casting is a liquid state method of composite materials fabrication, in which a
dispersed phase (ceramic particles, short fibers) is mixed with a molten matrix metal by means
of mechanical stirring. The liquid composite material is then cast by conventional casting
methods and
may also be
processed by
conventional
Metal
forming
technologies. Stir Casting is characterized by: content of dispersed phase is limited (usually
not more than 30 vol. %), distribution of dispersed phase throughout non-homogeneity of the
matrix , the presence of local clouds (clusters) of the dispersed particles (fibers); the presence
of the be gravity segregation of the dispersed phase due to a difference in the densities of the
dispersed and matrix phase. This technology is relatively simple and low cost. Therefore,
distribution of dispersed phase may be improved if the matrix is in semi-solid condition. The
method using stirring metal composite materials in semi-solid state is called Rheocasting. High
viscosity of the semi-solid matrix material enables better mixing of the dispersed phase.
1-Motor with stirring system,2-Heating Furnace,3-Crucible,4-Stirring blade,5-Plug.
The quality of composite castings produced in this process largely depends upon the
control of the processing parameters discussed below.
1. Metal casting temperature: The temperature at which the metal is poured into the
die cavity plays an important role on the casting quality and die life. The casting
temperature depends on the liquids temperature, the freezing range of the alloy, and
the die configuration. Low casting temperatures result in inadequate fluid life and
incomplete die fill. On the other hand, high casting temperatures would force the
metal to penetrate between the die and punch leading to metal flash or jamming of
the tooling.
2. Tooling temperature: High tooling temperatures would cause surface defects in
the castings. In some cases, welding may occur between the casting and the die
wall. Low temperature leads to premature solidification, thermal fatigue, and cold
laps. Temperatures of ~300 ° C or less are maintained for nonferrous alloys.
3. Melt quality and quantity: In this process, the metal is directly poured into the
cavity that has no gating or feeding system. Hence adequate precautions should be
taken to ensure that the material is free from any dross or suspended impurities.
Due to the absence of a gating system, the process requires precise quantity of metal
to be poured into the die cavity, which will otherwise change the casting
dimensions.
4. Die coating/lubricant: Die coating serves as a releasing agent and is selected
based upon the die material and the alloy composition. A commonly used die coat
is water-based colloidal graphite that is sprayed onto the die surface and the punch.
At high squeeze pressures, the coating may get stripped from the die surface
causing surface contamination. Hence, precaution should be taken in applying the
coating to the right thickness to ensure its desired performance.
5. Temperature for pressure application: The squeeze casting/infiltration process is
fully effective when the metal is completely in a liquid state. Hence, the control of
time delay between pouring and squeezing is very important and should be
minimized. Else, it may lead to reduction in the melt temperature leading to
premature solidification or incomplete infiltration of the preform.
6. Duration of pressure and pressure level: The applied pressure level depends on
the fluidity and the freezing range of the alloy. It also depends on the component
geometry and the alloy characteristics. Pressure in the range of about 30–110 MPa
is usually required to eliminate gas or shrinkage porosity. The duration of pressure
application depends on the alloy type and the heat transfer conditions. Prolonged
holding under pressure would cause die wall cracking and difficulty in the
withdrawal of the punch. A high applied pressure may also result in breakage of
the preform. Usually, a maximum pressure holding time of approximately 1 s/mm
section thickness of casting is employed.
7. Press speed: At high press speeds, the following may occur: metal flash at joints,
dilation of die parts and premature solidification at the impact zones due to
instantaneous peak pressures. Normally a two-speed action of rapid approach to
the metal surface followed by a slower impact speed is adopted.
8. Preform properties: Major factors to be considered are the full infiltration of the
preform (without damage or distortion) and the freezing of metal in the preform
with good interfacial contact between the matrix and the fiber. Insufficient
infiltration produces shrinkage pores that deteriorate the properties of the
composite. Further, the degradation of fibers by the melt depends on the exposure
time, squeeze infiltration temperature, wettability, and the bonding between the
fiber/ matrix at the interface. In addition, non-uniform distribution of fibers
(clustering) and large increase in applied pressure result in fiber degradation.
Figure 6 Squeeze Casting
3.2.3. Semi-Solid State Processes
In semisolid processes, incorporation of particles in matrix metal is conducted
when a matrix is in semisolid state (slurry), as it:
Facilitates uniform dispersion of reinforcements
Eliminates settling of denser reinforcement due to slurry state
Eliminates porosity (that usually occurs due to voids generated
at the molten metal/particle interface)
Semisolid processes are of two types, namely thixo-process/casting and rheo- processes
(compocasting). In thixo-casting process, addition of particles is carried out in matrix molten
state followed by agitation/vortex stirring of particles in slurry state, and then casting. In
rheocasting, incorporation of nanoparticles is done in the semisolid state of a matrix. A
combination of techniques such as semisolid processing (stirring) assisted by ultrasonic
vibration has been utilized to achieve effective dispersion when using nano-reinforcements
3.3. Mechanical and Microstructural Properties of
Light MMCs
“The attributes of Al and Mg composites are a combination of high specific stiffness,
excellent wear resistance, and the potential for relatively low-cost conventional processing. Al
and Mg composites have been under development for many years during which time a vast
number of different types of reinforcement have been attempted with varying degrees of
success. These include continuous fibers, short fibers, whiskers, and particles. Many different
matrices have been tried over the years and these have a bearing on some of the properties that
can be achieved in the composite. Tailoring the mechanical properties with respect to a specific
application can also be achieved by varying the type and amount of reinforcement, the choice
of matrix alloy, and the composite processing route. All these factors are interrelated and
should not be considered in isolation when developing a new material. Among the various
types of Al, Mg MMCs, the advantage of particulate reinforced composites are due to
processing, wherein conventional metal manufacturing methods and machining techniques can
be used.”
3.4. The Most Common MMCs Systems
Numerous combinations of matrices and reinforcements have been tried since work on
MMC began in the late 1950s. However, MMC technology is still in the early stages of
development, and other important systems undoubtedly will emerge. Numerous metals have
been used as matrices. The most important have been aluminum, titanium, magnesium, and
copper alloys and super alloys. The most important MMC systems are:
Aluminum matrix
1. Continuous fibers: boron, silicon carbide, alumina, graphite
2. Continuous fibers: alumina, alumina-silica
3. Whiskers: silicon carbide
4. Particulates: silicon carbide, boron carbide
Magnesium matrix
1. Continuous fibers: graphite, alumina
2. Whiskers: silicon carbide
3. Particulates: silicon carbide, boron carbide
Titanium matrix
1. Continuous fibers: silicon carbide, coated boron
2. Particulates: titanium carbide
Copper matrix
1. Continuous fibers: graphite, silicon carbide
2. Wires: niobium-titanium, niobium-tin
3. Particulates: silicon carbide, boron carbide, titanium carbide.
Super alloy matrices
Wires: tungsten
3
AMC: Aluminum Matrix Composites
3.5.1.1. Particle Reinforced Aluminum Matrix Composites (PAMCs)
These composites generally contain equiaxed ceramic reinforcements with an aspect
ratio less than about 5. Ceramic reinforcements are generally oxides or carbides or borides
(Al2O3 or SiC or TiB2) and present in volume fraction less than 30% when used for structural
and wear resistance applications. However, in electronic packaging applications reinforcement
volume fraction could be as high as 70%. In general, PAMCs are manufactured either by solid
state (PM processing) or liquid state (stir casting, infiltration and in-situ) processes. PAMCs
are less expensive compared to CFAMCs. Mechanical properties of PAMCs are inferior
compared to whisker/short fibre/continuous fibre reinforced AMCs but far superior compared
to unreinforced aluminium alloys. These composites are isotropic in nature and can be
subjected to a variety of secondary forming operations including extrusion, rolling and forging.
Figure 7 Microstructure of (a) aluminium matrix composite having high volume fraction of SiC
particle reinforcement (40 vol%), (b) short fibre-reinforced aluminium matrix composite, (c)
continuous fibre-reinforced aluminium matrix composite, (d) hybrid composite containing 10% SiC
and 4% graphite particles.