Metal Matrix Composites

Metal Matrix Composites

and their Automotive
and their Automotive
Applications
Applications
Eric Petersen
Eric Petersen
MatE
MatE
187
187
5/9/2007
5/9/2007
Outline
Outline
Introduction Introduction
Metal Matrix Metal Matrix
Reinforcement Reinforcement
Fabrication methods Fabrication methods
Properties of Automotive Properties of Automotive
MMC MMC s s
Applications Applications
Conclusion Conclusion
Introduction to
Introduction to
MMC
MMC

s
s

Metal Matrix composites have low volume
Metal Matrix composites have low volume
reinforcement in order to maintain metallic
reinforcement in order to maintain metallic
properties.
properties.

Ideal for lower density metals
Ideal for lower density metals

These composites find use in various
These composites find use in various
aspects of automotive design.
aspects of automotive design.

From high performance Formula 1 parts to
From high performance Formula 1 parts to
cheaper more reliable OEM replacement
cheaper more reliable OEM replacement
parts for consumer automobiles.
parts for consumer automobiles.
Engines, Brakes, and Engines, Brakes, and Drivetrain Drivetrain equipment equipment
Metal Matrix
Metal Matrix

The Matrix material typically consists of
The Matrix material typically consists of
Aluminum and Titanium.
Aluminum and Titanium.

Aluminum for Automotive industry (
Aluminum for Automotive industry (
AMC
AMC

s
s
)
)

Titanium for high performance needs
Titanium for high performance needs

Materials chosen based on criteria:
Materials chosen based on criteria:

Good strength/weight ratio
Good strength/weight ratio

Good thermal and mechanical properties
Good thermal and mechanical properties

Ease of fabrication and
Ease of fabrication and
machinability
machinability

Cheap and abundant
Cheap and abundant
Reinforcement
Reinforcement

Reinforcement methods include
Reinforcement methods include
continuous and discontinuous fibers and
continuous and discontinuous fibers and
particle.
particle.

Particle reinforcement provides manufactures
Particle reinforcement provides manufactures
with isotropic properties of metal with all the
with isotropic properties of metal with all the
benefits that the reinforcement offers.
benefits that the reinforcement offers.
SiC SiC, B , B
4 4
C, C, TiC TiC, , TiB TiB, TiB , TiB
2 2
, SiO , SiO
2 2
, Al , Al
2 2
O O
3 3
, , Fe Fe
2 2
O O
3 3
Volume usually never exceeds 20% vol. Volume usually never exceeds 20% vol.
Fabrication Methods
Fabrication Methods

Two methods:
Two methods:
Casting Casting
Reinforcement is compacted into a Reinforcement is compacted into a preform preform
The lighter metal is poured over in molten form The lighter metal is poured over in molten form
Pressure is applied and the two are mixed Pressure is applied and the two are mixed
Proper mixing is essential and wetting of the particles is Proper mixing is essential and wetting of the particles is
important important
Powder Metallurgy Powder Metallurgy
Powdered matrix metal and particulate reinforcement is Powdered matrix metal and particulate reinforcement is
compacted, sintered and/or forged. compacted, sintered and/or forged.
Allows for less expensive tooling Allows for less expensive tooling
Can be worked with more traditional fabrication methods Can be worked with more traditional fabrication methods
Properties of Automotive
Properties of Automotive
MMC
MMC

s
s

Properties that are improved
Properties that are improved
Specific stiffness (E/ Specific stiffness (E/ ) )
Specific strength Specific strength
Fatigue resistance Fatigue resistance
Wear resistance Wear resistance
Coefficient of thermal expansion Coefficient of thermal expansion
Thermal conductivity Thermal conductivity

MMC
MMC

s
s
maintain properties at a higher range
maintain properties at a higher range
of temperatures
of temperatures
Properties of Automotive
Properties of Automotive
MMC
MMC

s
s
Cont
Cont
Al with 20% Al with 20% vol vol SiC SiC
yield strength yield strength
increases by 50MPa increases by 50MPa
Tensile strength Tensile strength
increases by increases by
110MPa 110MPa
Titanium MMC with Titanium MMC with
10% 10% vol vol TiB TiB
maintain properties maintain properties
at temperatures over at temperatures over
800 800
o o
C C
Applications: Engine Block
Applications: Engine Block

Iron cylinder liner is
Iron cylinder liner is
replaced with AMC
replaced with AMC
Better thermal Better thermal
expansion coefficient expansion coefficient
Higher thermal Higher thermal
conductivity conductivity
Conducts combustion Conducts combustion
cycle heat to coolant cycle heat to coolant
Increases engine Increases engine
efficiency efficiency
1/3 the weight 1/3 the weight
Applications: Pistons and
Applications: Pistons and
Connecting Rods
Connecting Rods
AMC Pistons and AMC Pistons and
connecting rods connecting rods
Increased engine efficiency Increased engine efficiency
due to less rotating mass due to less rotating mass
$$$ reduced as less time is $$$ reduced as less time is
spent balancing rotating spent balancing rotating
parts parts
Lower thermal expansion Lower thermal expansion
allows for tighter tolerances allows for tighter tolerances
around the piston rings around the piston rings
Wear properties exceed cast Wear properties exceed cast
iron iron
Higher allowed temperatures Higher allowed temperatures
allow greater efficiency allow greater efficiency
Applications:
Applications:
Drivetrain
Drivetrain
Driveshafts Driveshafts, axles and , axles and
transmission parts achieve transmission parts achieve
greater critical speeds and greater critical speeds and
higher loads with higher loads with MMC MMC s s
Engine power is increased Engine power is increased
as higher critical speeds as higher critical speeds
are safely achieved are safely achieved
6061 Aluminum with 20% 6061 Aluminum with 20% vol vol
Al Al
2 2
O O
3 3
has a critical speed of has a critical speed of
6100rpm 17.3% higher than 6100rpm 17.3% higher than
that of conventional 6061 that of conventional 6061
(5200rpm) (5200rpm)
Applications: Braking Systems
Applications: Braking Systems

Braking systems
Braking systems
made from higher
made from higher
volume
volume
MMC
MMC

s
s
Resist wear mean Resist wear mean
longer life longer life
Unsprung Unsprung weight weight
increases engine increases engine
output output
More resistance to More resistance to
brake warping as brake warping as
thermal cycling doesn thermal cycling doesn t t
cause distortion cause distortion
Conclusion
Conclusion

Metal Matrix Composites maintain their metallic
Metal Matrix Composites maintain their metallic
properties and become valuable in automotive
properties and become valuable in automotive
applications
applications

Thermal and mechanical properties improved
Thermal and mechanical properties improved

Specific strength makes them ideal for OEM
Specific strength makes them ideal for OEM
replacement as well as high performance needs
replacement as well as high performance needs

Provide greater efficiency increasing output
Provide greater efficiency increasing output

Greater reliability reducing overall cost
Greater reliability reducing overall cost