1. Briefly explain the material selection considerations while tailoring MMC.

Composite materials:
• Metallic materials - predominantly: metallic bond, crystalline structure, good
conductivity, ductile, chemically unstable.
• Non-metallic materials - predominantly: unipolar and dipolar bonds, amorphous
structure, poor conductivity, high temperature ductile, chemically stable
• Ceramic materials - predominantly: amorphous or crystalline structure, poor
conductivity, non-ductile, chemically stable.

2. Which are the MMC reinforcements’ shapes?

• Dispersion hardened and particle composites
• Layer composites (laminates)
• Fiber composites
• Infiltration composites

3. Name several requirements imposed upon the MMC’ reinforcements.

• low density
• mechanically compatibility (a thermal expansion coefficient which is low but adapted to
the matrix)
• chemical compatibility
• thermal stability
• high Young’s modulus
• high compression and tensile strength1
• economic efficiency

4. Name several applications of MMC. Expand one of the reasons for which was the MMC
selected.
• Automotive applications – brake discs Lotus Elise – disc temperature: Tmax 380°C, Car
weight: <700 kg.
• Cylinder blocks and pistons - local reinforcement for wear and creep resistance.
• Railway applications - Brake discs weight of 74 kg (-38% vs. cast iron), and a total
weight saving >10 tons (192 discs)
5. Do you consider a larger market expansion regarding the MMC application?
• Yes, especially considering the market growth by more than 50% in the electronics
domain, together with the other growth in the transportation, aerospace, industrial, etc.
domains.

6. Sintering followed but a deformation procedure is called …? Can you underline few
differences among the particular procedures?
• Hot pressing fabrication of MMC - sintering under a unidirectional pressure applied by a
hot press.
• Hot isostatic extrusion fabrication of MMC - sintering under a pressure applied from
multiple directions through a liquid or gaseous medium surrounding the compacted part
and at elevated temperature.
• Hot powder extrusion fabrication of MMC - sintering under a pressure applied by an
extruder at elevated temperature.

7. What is the impact of economy of scale and the economy of scope on the automotive
manufacturing process?
• A better understanding of the manufacturing environment due to switch from the
economy of scale to an economy of scope to accommodate new demands from emerging
markets, mainly in Brazil, Russia, India, and China or the BRIC countries

8. List three challenges that have impacted the automotive industry in the past decade.
• Automotive designers and engineers have to understand the current
manufacturing infrastructure available, understanding design characteristics and
the overall cost.
• Designers should be aware that the vehicle design complexity in terms of number
of parts and intricate shapes results in additional manufacturing steps.
• New manufacturing and design strategies should be implemented and explored to
lessen complications in the manufacturing process.
9. Fill in the boxes to draw a complete painting booth layout (see fig.)