COMPOSITE MATERIALS AND TECHNOLOGY

CHAPTER - 1
METAL MATRIX COMPOSITES
1.1 INTRODUCTION
Composite materials are the material composed of two distinct phases (matrix phase and
dispersed phase) and having bulk properties significantly different from those of any of the
constituents.
Matrix phase - The primary phase, having a continuous character, is called matrix. Matrix
is usually more ductile and less hard phase. It holds the dispersed phase and shares a load
with it.
Dispersed (reinforcing) phase - The second phase (or phases) is embedded in the matrix
in a discontinuous form. This secondary phase is called dispersed phase. Dispersed phase is
usually stronger than the matrix, therefore it is sometimes called reinforcing phase.
CLASSIFICATION SYSTEMS OF COMPOSITE MATERIALS

Classification of composites (based on matrix material)

a) Metal Matrix Composites (MMC)

Fig 1.1
b) Ceramic Matrix Composites (CMC)
c) Polymer Matrix Composites (PMC)

Classification of composite materials (based on reinforcing material structure)

a) Particulate Composites
b) Fibrous Composites
c) Laminate Composites

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In Metal Matrix Composite, the matrix is a metal or its alloy. The performance of these
materials, i.e. their characteristics in terms of physical and mechanical properties, depends on
the nature of the two components (matrix and reinforcement).
In general we can say that metal matrix composites utilizes at the same time the properties of
the matrix (light weight, good thermal conductivity, ductility) and that of the reinforcement,
usually ceramic (high stiffness, high wear resistance, low coefficient of thermal expansion). By
this way it is possible to obtain better material characteristics, if compared to the basic metal
component.
MMCs v/s MONOLITHIC METALS
Higher strength- to- density ratios.
Higher stiffness-to-density ratios.
Better fatigue resistance.
Better elevated temperature properties.
Higher strength.
Lower coefficients of thermal expansion.
Better wear resistance.
Numerous combinations of matrices and reinforcement 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.

1.2 REINFORCEMENTS
Reinforcement materials in MMCs are discrete fibers or second phase additions to a metallic
matrix that result in a net improvement in some properties, typically an increase in strength
and/or stiffness. Most often reinforcement materials for MMCs are ceramics (oxides, carbides,
nitrides, etc.) which are characterized by their high strength and stiffness both at ambient and
elevated temperatures. Metallic reinforcements are used less frequently.
TYPES OF REINFORCEMENT
Reinforcements can be divided into five major groups.
a) Continuous fibers.
b) Discontinuous fibers.
c) Whiskers.
d) Particulates.
e) Wires.

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Fig 1.2
ROLE OF REINFORCEMENTS
The role of the reinforcement depends upon its type in structural MMCs. In particulate and
whisker reinforced MMC, the matrix is the major load bearing constituent. The role of the
reinforcement is to strengthen and stiffen the composite through prevention of matrix
deformation by mechanical restraint. This restraint is generally a function of the ratio of
interparticle spacing to particle diameter. In continuous fiber reinforced MMCs, the
reinforcement is the principal load-bearing constituent. The metallic matrix serves to hold the
reinforcing fibers together and transfer as well as distribute the load. Discontinuous fiber
reinforced MMCs display characteristics between those of continuous fiber and particulate
reinforced composites. Typically, the addition of reinforcement increases the strength, stiffness
and temperature capability while reducing the thermal expansion coefficient of the resulting
MMC. When combined with a metallic matrix of higher density, the reinforcement also serves
to reduce the density of the composite, thus enhancing properties such as specific strength.

1.3 REINFORCEMENT COATINGS

In many MMCs, it is necessary to apply a thin coating on the reinforcements prior to their
incorporation into the metal matrix.
In general, coatings on the fibers offer the following advantages:
a) Protection of fiber from reaction and diffusion with the matrix by serving as a diffusion
barrier.
b) Prevention of direct fiber-fiber contact.
c) Promotion of wetting and bonding between the fiber and the matrix.
d) Relief of thermal stresses or strain concentrations between the fiber and the matrix.
e) Protection of fiber during handling.
In some instances particulates are coated to enhance composite processing by enhancing
wetting and reducing interfacial reactions.

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There are several techniques available for the deposition of thin coatings on long fibers and, to
a much lesser extent, on short fiber and particulate reinforcement. One such process is
chemical vapor deposition (CVD). In this process, hot fiber is traversed through a reaction
zone in which a vaporized species either decomposes thermally or reacts with another vapor so
as to form a deposit on the fiber. Sometimes, the deposition process is enhanced by generating
electric discharge plasma (plasma-assisted CVD). Physical vapor deposition (PVD), plating
and spraying are some of the other techniques used to produce fiber coatings. Barrier coatings
must impair transport of reactants through it to protect fibers from chemical attack by the
matrix. Fluxing action by a reactive salt coating such as K2ZrF6 have been found to promote
wettability particularly for C and SiC fibers in aluminum.

1.4 CHARACTERISTICS AND DESIGN CONSIDERATIONS

The superior mechanical properties of MMCs drive their use. An important characteristic of
MMCs, however, and one they share with other composites, is that by appropriate selection of
matrix materials, reinforcements, and layer orientations, it is possible to tailor the properties of a
component to meet the needs of a specific design.
For example, within broad limits, it is possible to specify strength and stiffness in one direction,
coefficient of expansion in another, and so forth. This is rarely possible with monolithic
materials.
Monolithic metals tend to be isotropic, that is, to have the same properties in all directions. Some
processes such as rolling, however, can impart anisotropy, so that properties vary with direction.
The stress-strain behavior of monolithic metals is typically elastic-plastic. Most structural metals
have considerable ductility and fracture toughness.
The wide variety of MMCs have properties that differ dramatically. Factors influencing their
characteristics include:

Reinforcement properties, form, and geometric arrangement

Reinforcement volume fraction

Matrix properties, including effects of porosity

Reinforcement-matrix interface properties

Residual stresses arising from the thermal and mechanical history of the composite
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Possible degradation of the reinforcement resulting from chemical reactions at high

temperatures, and mechanical damage from processing, impact, etc.

Particulate-reinforced MMCs, like monolithic metals, tend to be isotropic. The presence of brittle
reinforcements and perhaps of metal oxides, however, tends to reduce their ductility and fracture
toughness. Continuing development may reduce some of these deficiencies.
The properties of materials reinforced with whiskers depend strongly on their orientation.
Randomly oriented whiskers produce an isotropic material. Processes such as extrusion can
orient whiskers, however, resulting in anisotropic properties. Whiskers also reduce ductility and
fracture toughness.
MMCs reinforced with aligned fibers have anisotropic properties. They are stronger and stiffer in
the direction of the fibers than perpendicular to them. The transverse strength and stiffness of
unidirectional MMCs (materials having all fibers oriented parallel to one axis), however, are
frequently great enough for use in components such as stiffeners and struts. This is one of the
major advantages of MMCs over PMCs, which can rarely be used without transverse
reinforcement.
Because the modulus and strength of metal matrices are significant with respect to those of most
reinforcing fibers, their contribution to composite behavior is important. The stress-strain curves
of MMCs often show significant nonlinearity resulting from yielding of the matrix.
Another factor that has a significant effect on the behavior of fiber-reinforced metals is the
frequently large difference in coefficient of expansion between the two constituents. This can
cause large residual stresses in composites when they are subjected to significant temperature
changes. In fact, during cool down from processing temperatures, matrix thermal stresses are
often severe enough to cause yielding. Large residual stresses can also be produced by
mechanical loading.
Although fibrous MMCs may have stress-strain curves displaying some nonlinearity, they are
essentially brittle materials, as are PMCs. In the absence of ductility to reduce stress
concentrations, joint design becomes a critical design consideration. Numerous methods of
joining MMCs have been developed, including metallurgical and polymeric bonding and
mechanical fasteners.

1.5 SELECTION PROCEDURE FOR MMCS

To select the best possible material for a given purpose among the large amount of existing
engineering materials, a systematic procedure is used which is natural to divide materials
section in to several stages.
a) The general function of the component (combination of properties).
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b)
c)
d)
e)
f)

The suggested geometrical form i.e., notch sensitivity or sensitive to crack initiation.
Service temperature (able to work at elevated temperatures).
The environment, the material will be exposed (chemical, radioactive or biological).
Mechanical loads on the component (durability).
Any special demands (electrical or thermal currents).

1.6 PRODUCTION TECHNOLOGIES

In general the most common manufacturing MMC technologies are divided primarily in to two
main parts:
a) The primary processing.
b) The secondary processing.
The primary processing is the composite production by combining ingredient material
(powdered metal and loose ceramic particles, or molten metal and fiber performs), but not
necessarily final shape or final microstructure. The secondary processing instead is the step
which obviously follows primary processing, and its aim is to alter the shape or microstructure
of the material (shape casting, forging, extrusion, heat- treatment, machining). Secondary
processing may change the constituents (phase, shape) of the composite.
These primary manufacturing processes can be classified into three types: Solid, Liquid, and
Vapor.
Solid state methods
o Powder blending and consolidation (powder metallurgy): Powdered metal and
discontinuous reinforcement are mixed and then bonded through a process of
compaction, degassing, and thermo-mechanical treatment (possibly via hot isostatic
pressing (HIP) or extrusion).
o Foil diffusion bonding: Layers of metal foil are sandwiched with long fibers, and then
pressed through to form a matrix.
Liquid state methods
o Electroplating / Electroforming: A solution containing metal ions loaded with
reinforcing particles is co-deposited forming a composite material.
o Stir casting: Discontinuous reinforcement is stirred into molten metal, which is
allowed to solidify.
o Squeeze casting: Molten metal is injected into a form with fibers preplaced inside it.
o Spray deposition: Molten metal is sprayed onto a continuous fiber substrate.
o Reactive processing: A chemical reaction occurs, with one of the reactants forming
the matrix and the other the reinforcement.
Vapor deposition
o Physical vapor deposition: The fiber is passed through a thick cloud of vaporized
metal, coating it.
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In situ fabrication technique

o Controlled unidirectional solidification of a eutectic alloy can result in a two-phase
microstructure with one of the phases, present in lamellar or fiber form, distributed in
the matrix.

The choice of production technology

Choice of the primary manufacturing process for the fabrication of any MMC is dictated by
many factors, the most important of which are:
a) Preservation of reinforcement strength
b) Minimization of reinforcement damage
c) Promotion of wetting and bonding between the matrix and reinforcement
d) Flexibility that allows proper backing, spacing and orientation of the reinforcements
within the matrix.

1.7 MATRIX MATERIALS AND KEY COMPOSITES

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 :
Continuous fibers: boron, silicon carbide, alumina, graphite.
Discontinuous fibers: alumina, alumina-silica.
Whiskers: silicon carbide.
Particulates: silicon carbide, boron carbide.

MAGNESIUM MATRIX :
Continuous fibers: graphite, alumina.
Whiskers: silicon carbide.
Particulates: silicon carbide, boron carbide.

TITANIUM MATRIX:
Continuous fibers: silicon carbide, coated boron.
Particulates: titanium carbide.

COPPER MATRIX :
Continuous fibers: graphite, silicon carbide.
Wires: niobium-titanium, niobium-tin.
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Particulates: silicon carbide, boron carbide, titanium carbide.

SUPERALLOY MATRICES:
Wires: tungsten.

1.8 APPLICATIONS
Carbide drills are often made from a tough cobalt matrix with hard tungsten carbide
particles inside.
Automotive disc brakes use MMCs. Modern high-performance sport cars, such as those
built by Porsche, use rotors made of carbon fiber within a silicon carbide matrix because
of its high specific heat and thermal conductivity.
Ford offers a Metal Matrix Composite (MMC) driveshaft upgrade. The MMC driveshaft
is made of an aluminum matrix reinforced with boron carbide, allowing the critical speed
of the driveshaft to be raised by reducing inertia. The MMC driveshaft has become a
common modification for racers, allowing the top speed to be increased far beyond the
safe operating speeds of a standard aluminum driveshaft.
Honda has used aluminum metal matrix composite cylinder liners in some of their
engines.
The F-16 Fighting Falcon uses monofilament silicon carbide fibers in a titanium matrix
for a structural component of the jet's landing gear.
Specialized Bicycles has used aluminum MMC compounds for its top of the range
bicycle frames for several years.

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