Metal Matrix Composites

Manufacturing and Characterization

Dr. Rajyalakshmi. G
Associate Professor
School of Mechanical Engineering
VIT University
Vellore
 CONTENTS
INTRODUCTION

CLASSIFICATION OF METAL MATRIX COMPOSITE

METAL MATRIX COMPOSITES (MMCs)

COMPOSITION

MATRIX..

REINFORCEMENT

PRODUCTION AND PROCESSING OF METAL MATRIX COMPOSITES

POSSIBLE APPLICATIONS OF METAL MATRIX COMPOSITES

ADVANTAGES OF MMCs

DISADVANTAGES OF MMCs

CHARACTERIZATION OF MMCS
 Introduction

Composite Man
 Introduction
The earliest man-made composite materials were straw
and mud combined to form bricks for building
construction.
 Concrete is also a composite material, and is
used more than any other man-made material
in the world. It consists of a binder
(cement) and a reinforcement (gravel).
Composite materials occur in nature. Wood
is a natural composite consisting of cellulose
as the fiber and lignin as the matrix.
 Why composites
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.
 Composite material
Composite materials are multi phase materials that exhibits a
significant proportion of the properties of both constituent
phases such that a best combination of properties is realized.

According to this principle of combined action, better property

combinations are fashioned by the judicious combination of
two or more distinct materials.

It is a multiphase material that is artificially made in which

the constituent phases must be chemically dissimilar and
separated by a distinct interface.
 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.
Many of common materials (metal 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 properties of steel are similar to those of
pure iron).
 Examples

Flesh in your leg reinforced with bones

Concrete reinforced with steel

Epoxy reinforced with graphite fibers

 Functions of the Matrix
Material (Primary Phase)
Provides the bulk form of the part or
product made of the composite material
Holds the imbedded phase in place, usually
enclosing and often concealing it
When a load is applied, the matrix shares the
load with the secondary phase, in some cases
deforming so that the stress is essentially
born by the reinforcing agent
 Functions of the Reinforcing
Phase (Secondary Phase)
Function is to reinforce the primary phase
Imbedded phase is most commonly one of the following
shapes:
Fibers
Particles
Flakes
In addition, the secondary phase can take the form of an
infiltrated phase in a skeletal or porous matrix
Example: a powder metallurgy part infiltrated with polymer
 The reinforcement of metals can have
many different objectives
Increase in yield strength and tensile strength at room
temperature and above while maintaining the minimum
ductility or rather toughness,
Increase in creep resistance at higher temperatures
compared to that of conventional alloys,
Increase in fatigue strength, especially at higher
temperatures,
Improvement of thermal shock resistance,
Improvement of corrosion resistance,
Increase in Youngs modulus,
Reduction of thermal elongation.
 Types of Composites
There are two classification systems
of composite materials.
One of them is based on the matrix
material (metal, ceramic, polymer) and the
second is based on the material structure
Classification of Metal Matrix
Composites
 Classification of composites I
(based on matrix material)
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.
Ceramic Matrix Composites (CMC)
Ceramic Matrix Composites are composed of a ceramic matrix and
embedded fibers of other ceramic material (dispersed phase).
Polymer Matrix Composites (PMC)
Polymer Matrix Composites are composed of a matrix
from thermoset (Unsaturated Polyester (UP), Epoxiy (EP))
or thermoplastic(Polycarbonate (PC), Polyvinylchloride, Nylon,
Polysterene) and embedded glass, carbon, steel or Kevlar fibers
(dispersed phase).
 Classification of composite materials II
(based on reinforcing material structure)

Particulate Composites
Particulate Composites consist of a matrix reinforced by a
dispersed phase in form of particles.
i. Composites with random orientation of particles.
ii. Composites with preferred orientation of
particles. Dispersed phase of these materials consists of two-
dimensional flat platelets (flakes), laid parallel to each other.
Fibrous Composites
Short-fibre reinforced composites. Short-fibre reinforced
composites consist of a matrix reinforced by a dispersed phase
in form of discontinuous fibres (length < 100*diameter).
Composites with random orientation of fibres.
Composites with preferred orientation of fibres.
Long-fibre reinforced composites. Long-fibre reinforced
composites consist of a matrix reinforced by a dispersed phase
in form of continuous fibres.
Unidirectional orientation of fibres.
Bidirectional orientation of fibres (woven).
 Metal Matrix Composites
MMCs are diverse class of materials .
Metal Matrix Composite (MMC) is a material
consisting of a metallic matrix combined with a ceramic
(oxides, carbides) or metallic (lead, tungsten,
molybdenum) dispersed phase.

Aluminium Matrix Composites (AMC)

Magnsium Matrix Composite
Titanium Matrix Composite
Copper Matrix Composites
 Metal Matrix Composites(MMCS)
MMCs offers a unique balance of physical and
mechanical properties.
MMCs Provide
High thermal and electrical conductivity,
Good resistance to aggressive environments
Good impact and erosion resistance
Good fatigue and fracture properties
Lower coefficient of thermal expansion
Excellent wear resistance
 Aluminium Metal Matrix
Composites (AMMC)
This is the widest group of Metal Matrix
Composites.

In AMMCs, the major constituent is aluminium alloy,

which forms percolating network and acts as the
matrix phase.

The other constituent embedded in the aluminium

alloy matrix and serves as reinforcement are usually
non metallic, and commonly include ceramics such as
Sic and Al2O3
 Aluminium Matrix Composites
(AMC) are reinforced by
Alumina (Al2O3) or silicon carbide (SiC)
particles (particulate Composites) in amounts
15-70 vol%;
Continuous fibers of alumina, silicon carbide,
Graphite (long-fiber reinforced composites);
Discontinuous fibers of alumina (short-fiber
reinforced composites)
 The following properties are typical for Aluminum
Matrix Composites

High strength even at elevated

temperatures;
High stiffness (modulus of elasticity);
Low density;
High thermal conductivity;
Excellent abrasion resistance.
 Applications of AMMCs
Aluminium Matrix Composites (AMC) are
used for manufacturing automotive parts
(pistons, pushrods, brake components),
brake rotors for high speed trains,
bicycles,
golf clubs, electronic substrates.
Fabrication methods of AMMCs
Powder metallurgy(sintering);
Stir casting;
Infiltration.
 Magnesium Matrix Composite
Magnesium alloys have been increasingly used in the
automotive industry in recent years due to their lightweight.

The density of magnesium is approximately two thirds of that

of aluminium, one quarter of zinc, and one fifth of steel.

As a result, magnesium alloys offer a very high specific

strength among conventional engineering alloys.

In addition, magnesium alloys possess good damping capacity,

excellent castability, and superior machinability.
 Magnesium Matrix Composite
Accordingly, magnesium casting production has experienced an
annual growth of between 10 and 20% over the past decades
and is expected to continue at this rate.
However, compared to other structural metals, magnesium alloys
have a relatively low absolute strength, especially at elevated
temperatures.
Currently, the most widely used magnesium alloys are based on
the Mg-Al system.
Their applications are usually limited to temperatures of up to
120C.
Further improvement in the high-temperature mechanical
properties of magnesium alloys will greatly expand their
industrial applications
 Reinforcing materials
Two types of reinforcing materials have been investigated for magnesium
matrix composites.
The first and most widely used is ceramics
Ceramic particles are the most widely studied reinforcement for magnesium
matrix composites.
Some common properties of ceramic materials make them desirable for
reinforcements.
These properties include low density and high levels of hardness, strength,
elastic modulus, and thermal stability. However, they also have some
common limitations such as low wettability, low ductility, and low
compatibility with a magnesium matrix.
Among the various ceramic reinforcements, SiC is the most popular because of
its relatively high wettability and its stability in a magnesium melt, as
compared to other ceramics.
 Because metallic solids will generally have a much better
wettability with liquid metals than ceramic powders, the
reinforcing of a magnesium matrix with
metallic/intermetallic particulates has recently been
examined.
Elemental metal powders, such as Cu, Ni, and Ti
particulates with a diameter of a few micrometers, have
been used as reinforcement agents in magnesium matrix
composites because of their high melting points and very
low solubility in magnesium.
The advantages of the metallic reinforcements lie in their
high ductility, high wettability and high compatibility with
the matrix as compared with ceramics, and their great
strength and elastic modulus as compared to the
magnesium matrix.
 Applications of MMMCs
Magnesium Matrix Compositesare used for
manufacturing components for racing cars,
lightweight automotive brake system,

aircraft parts for: gearboxes, transmissions,

compressors and engine
 Titanium Matrix Composite
Over the past 30 years, titanium metal matrix composites (Ti MMCs)
have been under considerable development and evaluation for use in
aircraft engine and airframe applications.

For airframers, the high specific modulus of Ti MMCs has been the
impetus, while engine makers have sought to take advantage of their
high specific strength, especially for compressor rotor applications.

Ti MMCs offer a potential 50% weight reduction in the hotter

compressor sections now dominated by nickel based super alloys.
Titanium Matrix Composites are
reinforced mainly by
Continuous monofilament silicon carbide
fiber (long-fiber reinforced composites);
Titanium boride (TiB2) and titanium carbide
(TiC) particles (particulate composites).
Powder metallurgy (sintering)is used for
fabrication of Titanium Matrix Composites.
 The following properties are typical for
Titanium Matrix Composites

High strength
High stiffness (modulus of elasticity)
High creep resistance
High thermal stability
High wear resistance
 Titanium Matrix Composites are used for

Manufacturing structural components of the F-16 jets

landing gear,
Turbine engine components (fan blades, actuator pistons,
Synchronization rings, Connecting links,Shafts, discs),
automotive engine components,
Drive train parts, general machine components.
Titanium reinforced with silicon carbide fibers is under
development as skin material for the National Aerospace
Plane.
 Copper Matrix Composites

Copper Matrix Composites are reinforced by:

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

Superalloy composites reinforced with tungsten alloy fibers

are being developed for components in jet turbine engines
that operate temperatures above 1,830 F.
 The following properties are typical for
Copper Matrix Composites

Low coefficient of thermal expansion;

High stiffness (modulus of elasticity);
Good electrical conductivity;
High thermal conductivity;
Good wear resistance.
 Copper Matrix Composites are
used for
Manufacturing hybrid modules,
Electronic relays,
Electrically conducting springs and other
electrical and electronic components
Applications of MMCs Proved
 Processing of Metal Matrix
Composites
Metal matrix composite materials can be produced by
many different techniques.
The focus of the selection of suitable process engineering
is the desired kind, quantity and distribution of the
reinforcement components (particles and fibers), the
matrix alloy and the application.
By altering the manufacturing method, the processing and
the finishing, as well as by the form of the reinforcement
components it is possible to obtain different characteristic
profiles, although the same composition and amounts of
the components are involved.
 Liquid-State Processes Casting
or liquid infiltration
It 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 methods of liquid state
fabrication
The methods of liquid state fabrication of Metal
Matrix Composites:

Stir Casting
Infiltration
Gas Pressure Infiltration
Squeeze Casting Infiltration
Pressure Die Infiltration
 Stir Casting
It 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.
Stir Casting is the simplest and the most cost
effective method of liquid state fabrication.
The liquid composite material is then cast by
conventional casting methods and may also be
processed by conventional Metal forming
technologies.
 Liquid-State Processes Casting
Infiltration
It is a liquid state method of composite materials
fabrication, in which a preformed dispersed phase (ceramic
particles, fibers, woven) is soaked in a molten matrix metal,
which fills the space between the dispersed phase inclusions.
The motive force of an infiltration process may be either
capillary force of the dispersed phase (spontaneous
infiltration) or an external pressure (gaseous, mechanical,
electromagnetic, centrifugal or ultrasonic) applied to the
liquid matrix phase (forced infiltration).
Infiltration is one of the methods of preparation of tungsten-
copper composites.
Liquid-State Processes Casting
or liquid infiltration
 THE CONTINUOUS PRODUCTION OF
METAL MATRIX COMPOSITES FROM
THE SEMISOLID STATE (1).mp4
 Gas Pressure Infiltration
Gas Pressure Infiltration is a forced infiltration method of
liquid phase fabrication of Metal Matrix Composites, using
a pressurized gas for applying pressure on the molten metal
and forcing it to penetrate into a preformed dispersed phase.
Gas Pressure Infiltration method is used for manufacturing
large composite parts.
The method allows using non-coated fibers due to short
contact time of the fibers with the hot metal.
In contrast to the methods using mechanical force, Gas
Pressure Infiltration results in low damage of the fibers.
Liquid-State Processes Casting
or liquid infiltration
 Liquid-State Processes
Squeeze casting or pressure infiltration
Squeeze Casting Infiltration is a forced
infiltration method of liquid phase fabrication of
Metal Matrix Composites, using a movable mold
part (ram) for applying pressure on the molten
metal and forcing it to penetrate into a performed
dispersed phase, placed into the lower fixed mold
part.
Squeeze Casting Infiltration method is similar to
the Squeeze casting technique used for
metal alloys casting.
 Squeeze Casting Infiltration
process has the following steps
A preform of dispersed phase (particles, fibers) is placed into the lower
fixed mold half.
A molten metal in a predetermined amount is poured into the lower mold
half.
The upper movable mold half (ram) moves downwards and forces the
liquid metal to infiltrate the preform.
The infiltrated material solidifies under the pressure.
The part is removed from the mold by means of the ejector pin.
The method is used for manufacturing simple small parts (automotive
engine pistons from aluminum alloy reinforced by alumina short
fibers).
Squeeze Casting & Semi-Solid Metal Processes.mp4
 Liquid-State Processes
Squeeze casting or pressure infiltration
 Solid state fabrication of
Metal Matrix Composites
It is the process, in which Metal Matrix Composites are
formed as a result of bonding matrix metal and dispersed
phase due to mutual diffusion occurring between them in
solid states at elevated temperature and under pressure.
Low temperature of solid state fabrication process (as
compared to Liquid state fabrication of Metal Matrix
Composites) depresses undesirable reactions on the
boundary between the matrix and dispersed (reinforcing)
phases.
 Metal Matrix Composites may be deformed also after
sintering operation by rolling, Forging,
pressing, Drawing or Extrusion.
The deformation operation may be either cold (below
the recrystallization temperature) or hot (above the
recrystallization temperature).
 There are two principal groups of solid state
fabrication of Metal Matrix Composites:

Diffusion bonding
Sintering
 Solid-State Processes
Diffusion Bonding
It is a solid state fabrication method, in which a
matrix in form of foils and a dispersed phase in
form of long fibers are stacked in a particular
order and then pressed at elevated temperature.
The finished laminate composite material has
a multilayer structure.
Diffusion Bonding is used for fabrication of
simple shape parts (plates, tubes).
 Solid-State Processes
Diffusion Bonding
Variants of diffusion bonding are roll bonding and wire/fiber
winding:
Roll Bonding is a process of combined Rolling (hot or cold)
strips of two different metals (e.g. steel and aluminum alloy)
resulted in formation of a laminated composite material with
a metallurgical bonding between the two layers.
Wire/fiber Winding is a process of combined winding
continuous ceramic fibers and metallic wires followed by
pressing at elevated temperature.

 Sintering
Sintering fabrication of Metal Matrix Composites is a process, in
which a powder of a matrix metal is mixed with a powder of dispersed
phase in form of particles or short fibers for subsequent compacting
and sintering in solid state (sometimes with some presence of liquid).
Sintering is the method involving consolidation of powder grains by
heating the green compact part to a high temperature below the
melting point, when the material of the separate particles diffuse to the
neighbouring powder particles.
In contrast to the liquid state fabrication of Metal Matrix Composites,
sintering method allows obtaining materials containing up to 50% of
dispersed phase.
 When sintering is combined with a deformation operation,
the fabrication methods are called:

Hot Pressing Fabrication of Metal Matrix Composites

Hot Isostatic Pressing Fabrication of Metal Matrix
Composites
Hot Powder Extrusion Fabrication of Metal Matrix
Composites
 Hot Pressing Fabrication of
Metal Matrix Composites
Hot Pressing Fabrication of Metal Matrix
Composites sintering under a
unidirectional pressure applied by a hot
press;
 Hot Isostatic Pressing Fabrication of
Metal Matrix Composites
Hot Isostatic Pressing Fabrication of Metal Matrix
Composites 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
Metal Matrix Composites

It is sintering under a
pressure applied by
an extruder at
elevated temperature.
 In-situ fabrication of Metal
Matrix Composites
It is a process, in which dispersed (reinforcing) phase is
formed in the matrix as a result of precipitation from the
melt during its cooling and Solidification.
Different types of Metal Matrix Composites may be
prepared by in situ fabrication method:
1. Particulate in situ MMC Particulate composite
reinforced by in situ synthesized dispersed phase in form of
particles.
Examples: Aluminum matrix reinforced by titanium boride
(TiB2) particles, magnesium matrix reinforced by Mg2Si
particles.
 Short-fiber reinforced in situ MMC Short-fiber composite
reinforced by in situ synthesized dispersed phase in form of short fibers
or whiskers (single crystals grown in form of short fibers).
Examples: Titanium matrix reinforced by titanium boride (TiB2) whiskers,
Aluminum matrix reinforced by titanium aluminide (TiAl3)
whiskers.
3. Long-fiber reinforced in situ MMC Long-fiber composite
reinforced by in situ synthesized dispersed phase in form of continuous
fibers.
Example: Nickel-aluminum (NiAl) matrix reinforced by long continuous
fibers of Mo (NiAl-9Mo alloy).
Dispersed phases of in situ fabricated Metal Matrix Composites may
consist of intermetallic compounds, carbides, borides, oxides, one
of eutectic ingredients.
 Advantages of in situ Metal Matrix Composites

In situ synthesized particles and fibers are smaller than those

in materials with separate fabrication of dispersed phase (ex-
situ MMCs).
Fine particles provide better strengthening effect
In situ fabrication provides more homogeneous distribution
of the dispersed phase particles;
Bonding (adhesion) between the particles of in situ formed
dispersed phase and the matrix is better than in ex-situ
MMCs;
Equipment and technologies for in situ fabrication of MMCs
are less expensive.
 Disadvantages of in situ Metal
Matrix Composites:
Choice of the dispersed phases is limited by
thermodynamic ability of their precipitation
in particular matrix;
The size of dispersed phase particles is
determined by solidification conditions;
 Composite Materials Test
Methods
Constituent Test Methods
Physical Test Methods for Composites
Mechanical Test Methods for Composites
Adhesives Testing
Test Methods for Sandwich Composites
Non-Destructive Testing
 Constituent Test Methods

Thermal/Physical testing Density,

Electrical Resistivity, Coefficient of Thermal
Expansion
Mechanical testing Tension, Compression,
Shear
 Matrix Characterization
Testing: Examples
Thermal Analysis
Glass Transition Temperature, Tg
Thermal expansion properties
Physical Testing
Matrix density ASTM D 792 or D 1505
Mechanical Testing (
Tensile properties - ASTM D 638
Compression, shear, flexure
 Physical Test Methods for
Composites
Density - ASTM D 792
Constituent content (fiber, matrix, voids)
Matrix digestion ASTM D 3171
Ignition loss ASTM D 2584
Image analysis
Flammability
Thermal cycling/microcracking
 Tensile Testing
Tensile testing utilizes the
classical coupon test
geometry as shown below and
consists of two regions:
a central region called the
gauge length, within which
failure is expected to occur,
and
the two end regions which are
clamped into a grip
mechanism connected to a test
machine.
 Compressive Testing
Composite compression test methods need to provide a
means of introducing a compressive load into the material
while preventing it from buckling
Shear loading methods IITRI(Illinois Institute of
Technology Research Institute compression test (ASTM D
3410)
End loading methods Modified ASTM D 695
Combined loading methods Combined Loading
Compression (CLC), ASTM D 6641
 Shear test

Most of the numerous shear test methods in existence measure intra-

laminar shear properties, rather than inter-laminar ones.
 Creep:
Creep Test of Metal Matrix Composites

Compression:
Compression Test of Metal Matrix Composite Coupon:

Unidirectional Coupon
Compression Test of Metal Matrix Composite Coupon:

Crossply Coupon
Compression Bearing Test of Metal Matrix Composite

Coupon
Filled Hole Compression Test of Metal Matrix

Composites Coupon
 Fatigue:
Unloaded Hole Fatigue of Metal Matrix Composites

Bearing Fatigue Test of Metal Matrix Composites

Fatigue Crack Growth in Metal Matrix Composites

Unnotched Tension Fatigue of Metal Matrix Composites

Fracture Toughness:
Monotonic Crack Growth (Fracture Toughness) in Metal

Matrix Composites
 Composite Tests.docx
 For Queries Can Contact at
rajyalakshmi@vit.ac.in