METAL MATRIX COMPOSITES

FROM SCIENCE TO
TECHNOLOGICAL SIGNIFICANCE

Presented by
Barada Prasanna Sahoo
School of Mechanical Engg.
Roll no- 1681074
 HISTORY OF MMC
• First emerged as a distinct technology for improvement in
military systems during the world war –II and in the cold war
period, but up to 1970 still was an immature technology.
• By the late 1980s the paradigm for material development and
commercialization began to change providing scope for
research and development of MMCs (National Aerospace
Plane (N.A.S.P) USA).
• The revival was spurred by efforts in discontinuously
reinforced MMCs which opened new faces of applications .
• After being solely used for their electromagnetic properties
(insulators and radar-domes), using composites to improve the
structural performance of spacecraft and military aircraft
became popular in the last two decades
 HISTORY OF MMC
• According to Tim Palucka and Bernadette Bensaude-Vincent,
Caltech, the evolution of composite (includes polymer,
ceramic, and metal matrices) materials can be divided into
four different generations.
• First Generation (1940s): Glass Fiber Reinforced Polymers
(GFRPs).
• Second Generation (1960s): High Performance Composites in
the post-Sputnik Era.
• Third Generation: The Search for New Markets and for the
Synergy of Properties (1970s & 1980s).
• Fourth Generation (1990s): Hybrids and Nano-composites.
• From above classification it is clear that MMC started its
journey from second generation and emerged after third
generation.
 TECHNOLOGICAL OVERVIEW
• Metal Matrix Composites generally consists of light weight
metal alloys of aluminum, magnesium or titanium reinforced
with particulate, whiskers or fibers.
• Factors that affects MMCs
1. In matrix department
a) differences in the matrix(such as heat treatment)
b) microstructure of matrix
c) matrix properties (physical, mechanical, chemical)
2. In reinforcement department
a) volume percentage b) aspect ratio c) particle size
d) reinforcement type e) orientation f) distribution
 CONTINUED…
3. other factors
a) fabrication method b) shape and thickness of specimen
c) interfacial bonds d) design of experiments e) coating
• The role of matrix in MMC may be summarized in three
distinct points
1. Provides the bulk form of the part or product made of the
composite material .
2. Holds the imbedded phase in place, usually enclosing and
often concealing it .
3. 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.
 CONTINUED…
. So while choosing matrix material special consideration must
be given , for example in case of continuous fiber reinforced
MMCs the composite strength will be primarily governed by
fiber strength so a lower strength, ductile and tougher matrix
alloy may be utilized while in case of discontinuously
reinforced MMCs the matrix may govern composite strength
so a higher strength matrix alloy may be suitable.
• The reinforcement type , size, orientation and quantity plays
an important role in composite properties. For example in
terms of tailorability particulate reinforcement provides
various properties than whiskers.
 CONTINUED…
Reinforcement types property

Particles Isotropic

Short fibers (random) Isotropic

Short fibers (aligned) Anisotropic

Continuous fiber Anisotropic

 CONTINUED…
• The general aspects of particle reinforced composite can be
characterized as low cost, high stiffness and strength, wear
resistance and simple manufacturing process. In case of
dispersed phase (particle dia. 10-250nm) dislocation is
blocked causing hardening. Generally provide better
properties than large particle reinforcement
• In case of fiber reinforcement better strength and stiffness is
achieved but in case of continuous fiber unidirectional
properties are far more superior than properties displayed in
transverse direction.
• So a lot of consideration is taken while using reinforcement
according to the desired properties expected from the
composite.
 PROPERTY COMBINATIONS OF COMMERCIAL AND
TECHNOLOGICAL IMPORTANCE
• MMCs offer a unique balance of physical and mechanical
properties. Along with the metallic alloys from which they
take their name.
• High thermal and electrical conductivity
• Good resistance to aggressive environments
• Good impact and erosion resistance
• Good fatigue and fracture properties
• High strength and stiffness
• Excellent wear resistance
• Lower coefficient of thermal expansion
• MMC properties can be varied over a very broad range that
spans metals and ceramics. This confers a degree of
tailorability that is unusual in engineering materials.
 PROPERTIES FOR STRUCTURAL APPLICATIONS
• Strength and stiffness are two most important characteristics
for structural applications.

Fig 1 Specific stiffness vs specific strength for structural

materials
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• The specific stiffness and specific strength are shown for fiber-
reinforced alloys of Al and Ti (the latter are often denoted as
TMCs), discontinuously reinforced Al (DRA), discontinuously
reinforced Ti (DRTi), conventional metals and graphite/epoxy
composites.
• From figure although graphite/epoxy provides the best
uniaxial strength and stiffness, it simultaneously provides the
poorest response in the transverse direction.
• Since structures must typically support multi-axial loads ,
Discontinuously reinforced MMCs provide competitive levels
of specific strength and stiffness (Fig. 1), and provide the
additional advantages of improved affordability and isotropy
in three-dimensions.
 CONTINUED…
• Further, structures often impose requirements in addition to excellent
specific stiffness and strength (such as bearing strength, resistance
to aggressive environment, resistance to out gassing etc.).
• MMCs typically provide superior response relative to organic matrix
composites in these areas.
• Fracture properties, such as ductility, toughness, impact resistance
and fatigue response, are often of primary importance for structural
applications.
• Initially although open literature abounds with reports of poor fracture
properties in MMCs, extensive research (reinforcement size, shape
and distribution) and the growing use of MMCs in fracture-sensitive
and fracture-critical applications provides sufficient evidence of the
confidence placed in the fracture properties of MMCs by the
engineering design community.
 PROPERTIES FOR THERMAL MANAGEMENT
• Thermal management is important in a wide range of applications, including
substrates for computer processor chips, power semiconductor devices and
packaging for microwave devices used in telecommunications.
• A high thermal conductivity (k) is required, and specific thermal conductivity
(k/ρ) is a useful property.
• Candidate electronic packaging materials must have values between 4 and
7 *10-6/K to match the CTE(α) of semiconductor materials and ceramic
substrates.
• Thermal management materials that perform best are those that possess a
CTE from 4 to 7 *10-6/K (indicated by the horizontal shaded band in Fig. 2)
and which have the highest value of k/ρ.
• Considering cost and risk in addition to CTE and k/ρ, Al/ SiC provides the
best overall figure of merit for thermal management materials
 CONTINUED…
• Kovar (an iron–nickel–cobalt alloy) is often used as a result of its acceptable
CTE, but its high density and marginal k give it a rather poor figure of merit.
• Improved performance is provided by Cu/W and Cu/Mo MMCs.

• Fig. 2. Materials comparison for thermal management applications.

. The best materials are those that have the highest values of k/ρ and fall
within the band of (α) illustrated by the horizontal shaded band.
 PROPERTIES FOR PRECISION DEVICES
• Many applications require exceptional resistance from distortion caused by
thermal and mechanical loads. Ex- atomic force microscope, robotic arms,
satellite antenna etc.
• Resistance to mechanical deflection mainly depends upon stiffness(E) and
density(ρ) where resistance to thermal distortion mainly depends upon
thermal conductivity (k) and coefficient of thermal expansion (α).
• The ideal material for precision devices must have high values of √E/ρ and
k/α.
• From figure 3 we can see that although axially reinforced graphite/epoxy
provides the best resistance to mechanical distortion but low value of k
provides the poorest resistance to thermal distortion.
• similarly although diamond and beryllium have all exceptional figures of
merits but poor fracture properties , cost and health issue makes them not
suitable for all applications
 CONTINUIED…
• Ceramic particle additions to a metal alloy produce only a
modest decrease in k and a small change in density , but
provides a significant decrease in CTE and a large increase in
stiffness thus making MMCs a candid material for precision
devices.

• Fig-3 Materials comparison for resistance to mechanical (vertical axis) and

thermal (horizontal axis) distortions.
 PROPERTIES FOR WEAR RESISTANCE
• Wear resistance is an important function in the balance of
properties provided by MMCs.
• The addition of hard reinforcements intrinsically improves the
wear resistance of the host metal. Further, additions such as
graphite can also provide intrinsic lubricity.
• MMC materials have been engineered to provide exceptional
wear resistance and represent an important family of
applications.
 MMC SYSTEMS OF COMMERCIAL IMPORTANCE
• MMCs of commercial importance represents a much smaller subset of its
applications but still covers a wide range. The diversity comes from the
large number of permutations of metal matrices and reinforcements and the
almost endless combinations of reinforcement size, morphology and
distribution.
• By far the largest commercial volumes are for DRA, which accounts for 69%
of the annual MMC production by mass followed by Cu MMCs (25%).
• The reinforcement of largest commercial volume is SiC followed by Al2O3
and TiC. Nearly all MMCs on commercial use rely on discontinuous
reinforcement, although applications exist for MMCs with continuous
ceramic fiber reinforcement. However a lot of research still needed for better
class MMCs.
• Super hard MMCs using Fe and Ni matrices TiC reinforcement have been
produced. Other MMCs are produced in small quantities for specialized
applications. Be/BeO P/M MMCs with 20 < Vf ≤ 60% BeO are used for
thermal management applications requiring the highest performance.
PRIMARY PROCESSES OF COMMERCIAL IMPORTANCE
• Of the commercial processes, liquid metal routes such as stir casting and
infiltration account for largest volume in primary production (67%). Powder
metallurgy (P/M) represents a small but important market.
• In stir casting process chemical reactivity, reinforcement size and density
are the important consideration. Products with Vf of reinforcement upto 40%
can be provided by this process and used where high production volume
and low cost is required. (mainly used for DRA MMCs)
• A ceramic Vf upto 70% can be used in liquid metal infiltration process. But
due to high ceramic volume percentage this is not appropriate for
components that require thermo mechanical deformation or for fracture
sensitive applications most widely used for MMCs with Al matrices.
• Powder metallurgy route are used to produce both continuous and
discontinuous reinforced MMCs. Less than 20% Vf of reinforcement used.
P/M DRA is an important commercial product for the aerospace and
motorsports industries due to a superior balance of properties.
 APPLICATIONS
• The MMC industry spans a significant range of applications. Insight on
some major market are provided below.
• A) Ground transportation-: 62% of annual MMC production by mass(1999)
The major applications served by MMCs in the automotive sector include
selectively reinforced pistons for diesel engines, selectively reinforced
cylinder bores in Al engine blocks, intake and exhaust valves, driveshaft's
and prop shafts, brake components (discs, rotors and calipers) and power
module components for hybrid and electric cars.
B) Thermal management -: 27% of MMC market by mass (1999) and
increased to 66% (2010).
A variety of thermal management components for high-end microprocessors
form the second major market segment. This includes power amplifier heat
sinks, heat sinks for integrated circuit packages, printed circuit board (PCB)
cores, cold plates, chip carriers, heat spreaders and rectifier packaging.
 CONTINUED…
• C) Aerospace -:Aerospace MMC applications comprised 5% by mass (1.4 ·
105 kg) and 14% by value ($15MUSD) of the worldwide MMC market in
1999 . And in the past 10 years it has increased to a great extent due to
continuous research and development in MMCs for better attributes.
• Aeronautical MMC applications have been established in the aerostructural,
aeropropulsion and subsystem categories.
• D) Industrial, recreation and infrastructure -: MMCs for industrial,
recreational and infrastructure applications comprise about 6% by mass and
about 13% by value of the MMC market.
• Industrial applications include cemented carbide and cermet materials,
electroplated and impregnated diamond tools, Cu and Ag MMCs for
electrical contacts etc
• recreational market include bicycle tubing, track spikes and lacrosse stick
shafts etc.
 FUTURE RESEARCH PRIORITIES

• From the early days when MMC was just a new concept in the material
world to today, a lot of improvement, research and developments have been
conducted.
• Now a days MMCs stand tall in the material world replacing monolithic
materials, but still a lot of area are still new and need extensive research.
• Some of the important fields are
1. Metal matrix nano composites
2. Modification of fabrication method (cheaper process with effective
dispersion)
3. Reinforcement Coating
4. Cheaper materials (development of lower cost fiber reinforcement)
5. Hybrid composites
 CONCLUDING REMARKS
• In the past 20 years, MMCs have progressed from primarily a
laboratory enterprise with only narrow commercial significance to a
diverse and robust class of materials with numerous important
applications across a number of commercial markets.
• The development of secondary manufacturing techniques and design
methodologies, along with standardization of materials, processes,
nomenclature and testing has aided this transformation.
• New MMC materials and architectures are transforming it to
advanced engineering materials for fifth generation .
• Still a lot of areas are new in MMC and new horizon of applications
are going to expand its market further..
 REFERENCES
• Miracle DB, Donaldson SL. Introduction to
composites. vol. 21. Materials Park: ASM
International; 2001.
• Kainer Ulrich Karl. Basics of Metal Matrix Composites
:2006
• Composite materials handbook by department of
defense (USA). Vol- 4, MIL-HDBK-17-4A, 2002
• Tavşanoğlu Tolga , metal matrix composites ,2014
THANK YOU