FACULTY OF ENGINEERING, ASSUIT

UNIVERSITY
MECHATRONICS AND ROBOTICS UNDERGRADUATE
STUDIES PROGRAM
MATERIALS SCIENCE AND ENGINEERING
UNDER SUPERVISION : PROF. IBRAHIM HASAB-ALLAH

PREPARED BY: AML NADY ASMAA WAJEAH

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

A composite material is a material made from two or more constituent materials

with significantly different physical or chemical properties that, when combined, produce a
material with characteristics different from the individual components. The individual
components remain separate and distinct within the finished structure, differentiating
composites from mixtures and solid solutions. “Composite composed of two or more distinct
phases (matrix phase, dispersed phase-reinforcing phase) and having bulk properties
significantly different from those of any of the constituents.
Many of common materials (metals, alloys, doped ceramics and polymers mixed
with additives) also have a small amount of dispersed phases in their structures, however they
 are not considered as composite materials since their properties are similar to those of their
base constituents (physical property of steel are similar to those of pure iron). Favorable
properties of composites materials are high stiffness and high strength, low density, high
temperature stability, high electrical and thermal conductivity, adjustable coefficient of
thermal expansion, corrosion resistance, improved wear resistance etc.” [1]
Composites, as engineering materials, usually have distinct characteristics which
high strength; high modulus; low density; excellent resistance to fatigue, creep, creep rupture,
corrosion, and wear; and low coefficient of thermal expansion (CTE). Composites are
artificially made (thus, excluding natural material such as wood). They consist of at least two
different species with a well-defined interface. Their properties are influenced by the volume
percentage of ingredients. These have at least one property not possessed by the individual
constituents. The performance of composite materials depends on properties of matrix and
reinforcement, size and distribution of constituents, shape of constituents, nature of interface
between constituents.

Figure 1 The General Composition of Composites

2.1. Classification of Composite Materials

Composites are classified on the basis of the matrix material and the filler materials. On
the basis of the matrix material, they are classified into metal-matrix composites, polymer
matrix composites, and ceramic matrix composites.
2.1.1. On the Basis of Matrix Material
In matrix-based structural composites, the matrix serves two paramount purposes;
binding the reinforcement phases in place and deforming to distribute the stresses among the
constituent reinforcement materials under an applied force. The demands on matrices are
many. They may need to temperature variations, be conductors or resistors of electricity, have
moisture sensitivity etc. This may offer weight advantages, ease of handling and other merits
which may also become applicable depending on the purpose for which matrices are chosen.
Solids that accommodate stress to incorporate other constituents provide strong bonds for the
reinforcing phase are potential matrix materials. A few inorganic materials, polymers and
metals have found applications as matrix materials in the designing of structural composites,
with commendable success. These materials remain elastic till failure occurs and show
decreased failure strain, when loaded in tension and compression.
 Figure 2 Matrix Materials Classification
2.1.1.a. Metal Matrix Composites (MMC)
Metal Matrix Composites are composed of a metallic matrix (aluminum, magnesium,
iron, cobalt, copper) and a dispersed ceramic (oxides, carbides) or metallic (lead, tungsten,
molybdenum) phase. MMCs typically use silicon carbide fibers embedded in a matrix made
from an alloy of aluminum and magnesium, but other matrix materials such as titanium,
copper, and iron are increasingly being used. Typical applications of MMCs include bicycles,
golf clubs, and missile guidance systems; an MMC made from silicon carbide fibers in a
titanium matrix is currently being developed for use as the skin (fuselage material) of the US
National Aerospace Plane.

2.1.1.b. Ceramic Matrix Composites (CMC)

Ceramic Matrix Composites are composed of a ceramic matrix and imbedded fibers of
other ceramic material (dispersed phase). CMCs are the third major type. Examples include
silicon carbide fibers fixed in a matrix made from a borosilicate glass. The ceramic matrix
makes them particularly suitable for use in lightweight, high-temperature components, such as
parts for airplane jet engines.

2.1.1.c. Polymer Matrix Composites (PMC)

Polymer Matrix Composites are composed of a matrix from thermoset (Unsaturated
polyester (UP), Epoxy) or thermoplastic (PVC, Nylon, Polystyrene) and embedded glass,
carbon, steel or Kevlar fibers (dispersed phase).

2.1.2. On the Basis of Filler Material

Reinforcements for the composites can be fibers, fabrics particles or whiskers. Fibers
are essentially characterized by one very long axis with other two axes either often circular or
near circular. Particles have no preferred orientation and so does their shape. Whiskers have a
preferred shape but are small both in diameter and length as compared to fibers. Reinforcing
constituents in composites, as the word indicates, provide the strength that makes the
composite what it is. But they also serve certain additional purposes of heat resistance or
conduction, resistance to corrosion and provide rigidity. Reinforcement can be made to
perform all or one of these functions as per the requirements. A reinforcement that embellishes
the matrix strength must be stronger and stiffer than the matrix and capable of changing failure
mechanism to the advantage of the composite. This means that the ductility should be minimal
or even nil the composite must behave as brittle as possible.

Figure 3 Reinforcement Classification

2.1.2.a. Particulate Composites
Particulate Composites consist of a matrix reinforced by a dispersed phase in form of
particles. Composites with random orientation of particles. Composites with preferred
orientation of particles. Dispersed phase of these materials consists of two-dimensional flat
platelets (flakes), laid parallel to each other.

2.1.2.b. Fibrous Composites

The orientation of the fiber in the matrix is an indication of the strength of the composite
and the strength is greatest along the longitudinal directional of fiber. This doesn’t mean the
longitudinal fibers can take the same quantum of load irrespective of the direction in which it
is applied. Optimum performance from longitudinal fibers can be obtained if the load is applied
along its direction. The slightest shift in the angle of loading may drastically reduce the strength
of the composite.
There are short-fiber reinforced composites and long-fiber reinforced composites. Short-
fiber reinforced composites consist of a matrix reinforced by a dispersed phase in form of
discontinuous fibers (length < 100*diameter). There are composites with random orientation
of fibers and preferred orientation of fibers. Long-fiber reinforced composites consist of a
matrix reinforced by a dispersed phase in form of continuous fibers. They could be
unidirectional orientation of fibers or bidirectional orientation of fibers (woven).
2.1.2.c. Laminate Composites
Laminates are composite material where different layers of materials give them the
specific character of a composite material having a specific function to perform. When a fiber
reinforced composite consists of several layers with different fiber orientations, it is called
multilayer (angle-ply) composite.

3. Metal Matrix Composites (MMCs)

Metal Matrix Composites (MMCs)1 are composed of a metallic matrix (Al, Mg, Fe, Cu,
etc.) and a dispersed ceramic (oxide, carbides) or metallic phase (Pb, Mo, W, …). Ceramic
reinforcement may be silicon carbide, boron, alumina, silicon nitride, boron carbide, boron
nitride etc. whereas Metallic Reinforcement may be tungsten, beryllium, etc. MMCs are used
for Space Shuttle, commercial airliners, electronic substrates, bicycles, automobiles, golf clubs
and a variety of other applications. From a material point of view, when compared to polymer
matrix composites, the advantages of MMCs lie in their retention of strength and stiffness at
elevated temperature, good abrasion and creep resistance properties. Most MMCs are still in
the development stage or the early stages of production and are not so widely established as
polymer matrix composites. The biggest disadvantages of MMCs are their high costs of
fabrication, which has placed limitations on their actual applications. The metal matrix is a
ductile metal. These materials may be used at higher service temperatures than their base-metal
counterparts; furthermore, the reinforcement may improve specific stiffness, specific strength,
abrasion resistance, creep resistance, thermal conductivity, and dimensional stability.” [1][4]
The choice of a matrix alloy for an MMC is dictated by several considerations. Of
particular importance is whether the composite is to be continuously or discontinuously
reinforced. The use of continuous fibers as reinforcements may result in transfer of most of
the load to the reinforcing filaments and hence composite strength will be governed primarily
by the fiber strength. The primary roles of the matrix alloy then are to provide efficient transfer
of load to the fibers and to blunt cracks in the event that fiber failure occurs and so the matrix
alloy for continuously reinforced composites may be chosen more for toughness than for
strength. On this basis, lower strength, more ductile, and tougher matrix alloys may be utilized
in continuously reinforced composites. For discontinuously reinforced composites, the matrix
may govern composite strength. Then, the choice of matrix will be influenced by consideration
of the required composite strength and higher strength matrix alloys may be required.
Additional considerations in the choice of the matrix include potential
reinforcement/matrix reactions, either during processing or in service, which might result in
degraded composite performance; thermal stresses due to thermal expansion mismatch
between the reinforcements and the matrix; and the influence of matrix fatigue behavior on the
cyclic response of the composite. Indeed, the behavior of composites under cyclic loading
conditions is an area requiring special consideration. In composites intended for use at

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.

Figure 5 Stir Casting

STRENGTHENING MECHANISM OF COMPOSITES

The strengthening mechanisms of the composites are different with different kind of
reinforcing agent morphology such as fibers, particulate or dispersed type of reinforcing
elements. Strengthening mechanism of fiber reinforced composite, in such type of composite,
the reinforcing phase carries the bulk of the load and the matrix transfers the load to the
reinforcing phase by the mechanism of seam. The high strength of the reinforcing phase
restricts the free elongation of the matrix especially in its vicinity, whereas later is free to
elongate at some distance away from the former. This type of non-uniform deformation of the
matrix leads to a shear stress at the matrix reinforcement interface which results tensile stress
at the reinforcing phase. Thus, the stress is transferred to the reinforcing phase.
The fibers either may be continuous or discontinuous in the matrix. In the former case
the load is directly applied to the reinforcing phase and stress is constant over its entire length.
In case of discontinuous fibers, the stress in the fiber increased from zero value at the end to a
maximum value in the center and thus average tensile strength developed is always less than
those of continuous fibers. For the same when the fracture of the reinforcing phase, therefore
the strength of the discontinuous fiber reinforced composite increases with increasing the
length of the fiber and artifacts that of the continuous fiber reinforced one. Also the strength
of the fiber reinforced composite will be maximum when the fibers are aligned in the direction
of the applied stress i.e. in the isostrain condition. So the strength of this kind of composite
depends on the volume fraction of the reinforcing element present in the composite, which can
be determined by the simple rule of mixtures.

DISPERSION STRENGTHENING MECHANISM OF STRENGTHENED

COMPOSITE
In the dispersion strengthened composite the second phase reinforcing agents are finely
dispersed in the soft ductile matrix. The strong particles restrict the motion of dislocations and
strengthen the matrix. Here the main reinforcing philosophy is by the strengthening of the
matrix by the dislocation loop formation around the dispersed particles. Thus the further
movement of dislocations around the particles is difficult. Degree of strengthening depend
upon the several factors like volume % of dispersed phase, degree of dispersion, size and shape
of the dispersed phase, inter particle spacing etc. In this kind of composite, the load is mainly
carried out by the matrix materials.
STRENGTHENING MECHANISM OF PARTICULATE COMPOSITE
In the particulate reinforced composite, the size of the particulate is more than 1 µm, it
strengthens the composite in two ways. First one is the particulate carry the load along with
the matrix materials and another way is by formation of incoherent interface between the
particles and the matrix. So a larger number of dislocations are generated at the interface, thus
material gets strengthened. The degree of strengthening depends on the amount of particulate
(volume fraction), distribution, size and shape of the particulate, etc.
3.2.2.b. Squeeze Casting
This process involves the infiltration of a molten alloy into a ceramic fiber/particle
preform followed by solidification. The introduction of molten metal into a preform could be
achieved either through pressureless infiltration or by infiltration under pressure. In pressure
less infiltration, ceramic fiber bundles are first placed in the die. The molten metal is then
poured on to it and allowed to solidify. The solidified composites are then hot pressed to
achieve 100 % density. The initial infiltration occurs without any application of external
pressure and the wettability of fibers ensures efficient infiltration. The pressure infiltration
process can be employed in two different ways, namely via gas infiltration and pressure
infiltration. In gas infiltration, vacuum or inert gas atmosphere is utilized to bring forth
infiltration. Advantages of this method include increase in the wettability due to the increased
surface activity of reinforcement in vacuum environment, elimination of gas entrapment or
porosity and achieving near-net shaped components. Its main disadvantages are segregation of
phases and reaction between matrix/fiber due to the slow nature of the process. The squeeze
infiltration process involves the infiltration of molten metal into a ceramic preform using
hydraulic pressure. By this method, the drawbacks of phase segregation and matrix/interface
reaction encountered in gas infiltration can be eliminated due to the application of hydraulic
pressure (as it increases the solidification rate). To note, preforms are usually prepared using
ceramic reinforcements having aspect ratios (e.g., alumina short fibers). For nanoscale
reinforcements, CNTs are used as preforms for they have dimensional anisotropy (i.e., aspect
ratio). However, preparation of CNT preforms is a major challenge. In both cases, an
improperly made preform can cause local inhomogeneous distribution of reinforcement fibers
causing large variation in the volume fraction within a solidified composite. Also, in case that
the preform is not well prepared (such as insufficient binder), it has a tendency to break during
the application of squeeze pressure.

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

3.5. Aluminum-Matrix Composites

In AMC3s one of the constituent is aluminum/aluminum alloy, which forms percolating
network and is termed as matrix phase. The other constituent is embedded in this
aluminum/aluminum alloy matrix and serves as reinforcement, which is usually non-metallic
and commonly ceramic such as SiC and Al2O3. Properties of AMCs can be tailored by varying
the nature of constituents and their volume fraction. The major advantages of AMCs compared
to unreinforced materials are as follows:
 Greater strength
 Improved stiffness
 Reduced density(weight)
 Improved high temperature properties
 Controlled thermal expansion coefficient
 Thermal/heat management
 Enhanced and tailored electrical performance
 Improved abrasion and wear resistance
 Control of mass (especially in reciprocating applications)
 Improved damping capabilities.
These advantages can be quantified for better appreciation. For example, elastic
modulus of pure aluminum can be enhanced from 70GPa to 240GPa by reinforcing with 60
vol.% continuous aluminum fiber. On the other hand incorporation of 60 vol% alumina fibre
in pure aluminum leads to decrease in the coefficient of expansion from 24 ppm= _C to 7
ppm= _C. Similarly it is possible to process Al-9% Si-20 vol% SiCp composites having wear
resistance equivalent or better than that of grey cast iron. All these examples illustrate that it
is possible to alter several technological properties of aluminum/aluminum alloy by more than
two– three orders of magnitude by incorporating appropriate reinforcement in suitable volume
fraction.
3.5.1. Types of AMCs
AMCs can be classified into four types depending on the type of reinforcement.
 Particle-reinforced AMCs (PAMCs)
 Whisker-or short fiber-reinforced AMCs (SFAMCs)
 Continuous fiber-reinforced AMCs (CFAMCs)
 Mono filament-reinforced AMCs (MFAMCs)

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.

3.5.1.2. Short Fibre- and Whisker-Reinforced Aluminium Matrix Composites

(Sfamcs)
These contain reinforcements with an aspect ratio of greater than 5, but are not
continuous. Short alumina fibre reinforced aluminium matrix composites is one of the first and
most popular AMCs to be developed and used in pistons. These were produced by squeeze
infiltration process. Figure 1b shows the microstructure of short fibre reinforced AMCs.
Whisker reinforced composites are produced by either by PM processing or by infiltration
route. Mechanical properties of whisker reinforced composites are superior compared to
particle or short fibre reinforced composites. However, in the recent years’ usage of whiskers
as reinforcements in AMCs is fading due to perceived health hazards and, hence of late
commercial exploitation of whisker reinforced composites has been very limited. Short fibre
reinforced AMCs display characteristics in between that of continuous fibre and particle
reinforced AMCs.

3.5.1.3. Continuous Fibre-Reinforced Aluminium Matrix Composites (CFAMCs)

Here, the reinforcements are in the form of continuous fibres (of alumina, SiC or carbon)
with a diameter less than 20 _m. The fibres can either be parallel or pre woven, braided prior
to the production of the composite. AMCs having fibre volume fraction upto 40% are
produced by squeeze infiltration technique. More recently 3MTm corporation has developed
60 vol% alumina fibre (continuous fibre) reinforced composite having a tensile strength and
elastic stiffness of 1500 MPa and 240 GPa respectively. These composites are produced by
pressure infiltration route.
 3.5.1.4. Mono Filament Reinforced Aluminium Matrix Composites (MFAMCs)
Monofilaments are large diameter (100 to 150 _m) fibres, usually produced by chemical
vapor deposition (CVD) of either SiC or B into a core of carbon fibre or W wire. Bending
flexibility of monofilaments is low compared to multifilament. Monofilament reinforced
aluminum matrix composites are produced by diffusion bonding techniques, and is limited to
super plastic forming aluminium alloy matrices.

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.

In CFAMCs and MFAMCs, the reinforcement is the principal load-bearing constituent,

and role of the aluminium matrix is to bond the reinforcement and transfer and distribute load.
These composites exhibit directionality. Low strength in the direction perpendicular to the
fibre orientation is characteristic of CFAMCs and MFAMCs. In particle and whisker
reinforced AMCs, the matrix is the major load-bearing constituent. The role of the
reinforcement is to strengthen and stiffen the composite by preventing matrix deformation by
mechanical restraint.
 References
1. S.Kumar and J.J.Theerthan.2008. A paper on “Metal Matrix Composites”.
2. M.K. Suparra. 2013. A paper on “Aluminum-Matrix Composites: Challenges and
Opportunities”.
3. “Materials Science and Engineering_ An Introduction” W.D.Callister and D.Rethwisch.
Jon Wiley & Sons publishing. 9th edition.2013.
4. S.Trinh. 2016. A paper on “Processing and Properties of Metal Matrix Composites”.