UNIT II

METAL MATRIX COMPOSITE

3.1 INTRODUCTION
. Composites can be classified into three broad types depending upon the type of
matrix used.
1. Polymer Matrix Composite (PMC)
2. Metal Matrix Composite (MMC)
3. Ceramic Matrix Composite (CMC)
Composites

Metal Ceramic Polymetric

matrix matrix matrix
composites composites Composites

Fig. 3.1
" So, in Metal Matrix Composite, we use metal as a matrix.
" Metal matrix composites consist of a metal or an alloy as the continuous matrix and a reinforcement that can be
particle, short fiber or whisker, or continuous fiber. Metals generally have very high temperature as compared to that
of polymer composites.
Historical Perspective:
" In 1970s, the cold war forces development of metal matrix composites for military aircraft and missile guidance
systems came into existence. So, metal matrix composites somewhere in 1970s, it picked up and it started getting into
action.
Appliance
& business
equipment Other
5%
4/
Consumer
products
6%
Transportation
Electrical 31%
&electronics
10%

Corrosion
resistant
equipment
12%

Marine Construction
12%
20%
Fig. 3.2
In transportation industry it was round about 31 percent.
*So, majority came from transportation industry, then came few in construction industry, then in marine then corrosion
resistance equipment which came which was around aboutl2 percent and electrical and electronic are 10 percent,
then we have other businesses which were close to 4 percent.
(3.1)
 METAL MATRIX COMPOS

COMPOsITE MATERIALS (3.2)

What are Metal Matrix constituent parts -a metal

Composites? containing at least
two
pan.
material to
Metal matrixcomposites (MMCs) are composite
a material or a different metal part. The metal matrix is
materials
reinforced with the
other improve strengh,
Metal Most
wear. matrixmetals
composites (MMCs)
and allovs are amatrices.
make g00d class of lightweight and high-specific strength materials having nume
management.
industrial applications especially in automotive, aerospace and thermal strength, wear
capable of displaying improved and c
Metal matrix composites are advanced engineered materials wide range of
resistance, excellent damping and reduced thermal expansion
making them suitable
fora
marine, and packaging industries.
applicaticr
aerospace,
defense, space,
transportation, cutting tools, consumer electronics,
Metal Matrix Composites (MMC)
one being a
(MMC) is composite materials with at least two constitutent parts,
e arix composite
other material may be a different metal or another material, such as a ceramCs or organic compotr
ecessdy, tne
Reainforcement: Alumina, Sic, Zirconia, TiN, CBN (Cubic boron nitride) et.
Matrix : Aluminum, Steel Magnesium, Titanium, Cobait and Cobalt-nickel etc.
Metal matrix composites (MMCs)

Matrix
Reinforcement

" Aluminium MMC Alumina

"Magnesium "SiC
" Titanium "Zirconia
"Cobalt " TiN
" Cobalt-nickel etc. " CBN etc.

Fig. 3.3
The main matrix materials employed in MMCs are aluminium, titanium, magnesium, and copper. The m
reinforcements employed are silicon carbide and alumina.
The structural and functional properties of MMCs can be tailored according to the demands of various industre
anplications by selecting suitable combinations of matrix, reintorcement and processing route.
In structural applications, the matrix is usually composed of a lighter metal such as magnesium.
titanium, or alumi
In high-temperature applications, cobalt and cobalt-nickel alloy matrices are
common. ContinuQus carbon, Sls
carbide, or ceramic fibers are some of the materials that can be embedded in a
metallic matrix material.
For example, MMCs are increasingly found in the automotive industry. These materials use a metal Such as aluminu
Se the matrix, and reinforce it with fibers such as silicon carbide. The space era bas
.bat
increased the demand for M
nossess highspecific stiffness and near-zero coefficient of thermal expansion (CTEL
fercement. the matrix, and the intertace between them
determine the characteristics of MMCs.
The use of a metal mnatrix offeers the potential of producing a composite with very high stiffness and strengtn as well2
resistance.
very high temperature
 cOMPOsITE MATERIALS
(3.3) METAL MATRIX COMPOsITE

2 CHARACTERISTICS OF METAL
MATRIX COMPOSITES
Metal matrices possess the advantage of being suitable for use in applications
requiring a long-term resistance to severe
environments over polymeriC matrices. It is a fact that the vield strength and modulus of most metals are higher than
those for polymers. Another advantage of using metals is that they can be
plastically deformed and strengthened by many
thermal and mechanical treatments. The characteristics of MMCs can be designed into the material
applications.
based on specitic
The following are some key material properties benefits of
MMCs:
Fire resistant.

Operate in wider range of temperatures.

Do not absorb moisture,
Better electrical and thermal conductivity.
Resistant to radiation damage.
Low CTE and light weight.
. Good damping and high
compression strength.
. High specific stiffness and strength.
Metal matrix composites (MMCS), by virtue of their low density, high
strength-to-weight ratio, high
retention, and excellent creep, fatique, and wear resistances, have the potential for replacing cast temperature strengtn
iron and other materials
in engines and brakes.
3.3 ADVANTAGES AND LIMITATIONS OF METAL MATREX
COMPOSITES
3.3.1 Advantages of Metal Matrix Composites
" Higher specific strength and modulus over metals.
Lower coefficients of thermal expansion than metals by reinforcing with graphite.
Maintenance of high strength properties at high temperatures.
" Higher temperature capability.
" First resistance.
" Higher transverse stiffness and strength.
" No moisture absorption.

" Higher electrical and thermal conductivities.

No moisture absorption.
Higher electrical and thermal conductivities.
Better radiation resistance.
Higher specific strength and modulus over metals.
Lower coefficients of thermal expansion than metals by reinforcing with graphite.
Fabric ability of whiskerand particulate-reinforced MMC's with conventional metalworking equipment.
S3.2 Limitations of Metal Matrix Composites
Higher cost of some material systems.
Relatively immature technology.
Complex fabrication methods for fiber-reinforced systems (except for casting).
Limited service experience.
 METAL MATRIX CoOMPO
COMPOosITE MATERIALS (3.4)
In fire, can operate in
comparison with absorb moisture,
temperatures, do not conventional polynmer bettercomposites,
havematriN
MMCs are resistant to
electrical and thermal conductivity, are resistarnt wider tane.
to radiation dar.

and do not display out gassing. On expensive, the fiber-reinforcer

the other hand, MMCs tend to be more
be difficult to fabricate, and the available experience in use
Applications of Metal Matrix Composites:
is limited. materia,

Fig. 3.4
Aerospace industry wanted to have high strenath. So, high strength they want and then they want high stiffness, the
wanted to have low coefficient of thermal expansion and it has to be light weight. Because if you can reduce one are
or even five grams of weight here in aerospace industry you make a huge savings in your
fuel because here you ha
to carry your fuel and go.
Here Aluminium matrix is used, titanium is used, magnesium is used and high entropy
alloys are also used so that the
form composites.

Fig. 3.5
The brake drum is made out of metal
matrix composite earlier it was made out of cast iron nOw it is made out o
matrix. composite wheel rim titanium rim are coming up .
niston which is there for a long time which is today with metal matrix
coming out of metal matrix composite and then you w"
Eront and rear discs are completely made out of metal composites
matrix composite
Drive shaft is another big example.
This is an engine block which waswas earlier made
out of cast iron fromn peopleart
titanium and from there it went into
making it out of when Aluminium and titanium are mixed are made. So. Aluminium todaygetingi
the field called as metal matrix composites. So, here they are slowY
Aluminium reinforced with SiC is done.
 cOMPOsITE MATERIALS
(3.5) METAL MATRIX COMPOSITE

. In Railways, br aking diSC and baking drums are today madde out of metal rmatriy Cornposite. So, they are
made
lightweight so that they can increase the milecaae So liabtweinht is made and it can
withstand high temperatures

(5%) Other
10 Steel
(Primarily landing gear)

50%
15%)Titanium Advaniced
composites

209 Aluminium

Fig. 3.6

as turbine can be used in aerospace; it can be used in marine industry. High strength, low weight, ability to perform at
igh temperature makes metal matrix composite the material or Choice for gas turbine engine components.
 METAL.MATRIX COMPO
COMPOSITE MATERIALS (3.6) materials:
composite metal matrix
The following are some of the most common application areas of
Pushrods for racing engines
Carbide drills
Tank armors

Automotive industry - disc brakes, driveshaft, engines

Aircraft components - structural component of the jet's landing gear
Bicycle frames
Space systems
High density multi-chip modules in electronics
Parts in particle accelerators
Attach plates for high-speed robots
Reinforcements for Metal Matrix Composites:
The following denmands are generally applicable:
Low density
Mechanical compatibility
Thermal stability
High Young's Modulus
High Compression and tensile strength
Good process ability
Economic efficiency
The reinforcement material is embedded into the matrix to enhance or even reduce if you want reduce the
wear, properties i
resistance, hardness, density, porosity, mechanical strength, thermal
expansion, contraction on electria
conductivity.
3.4 TYPES OF METAL MATRIX
COMPOSITES
Metal matrix composite
(MMCs)

Particles reinforced Short fibers

or
(MMCs) whiskers reinforced Continues fibers or
sheet reinforced
MMCs
MMCs

Particles Short fibers or

whiskers Continues fibers
Metal Matrix Composites are further classified into: Fig. 3.7 Sheet laminates
1. Particle reinforced MMCs
2. Short fibers or whiskers reinforced MMCs
3 ContinuOus fibers or sheet reinforced MMCe
 cOMPOSITE MATERIALS METAL MATRIX COMPOSITE
(3.7)
Table 3.1: Typical reinforcoments used in metal matrix composites
Type Aspect ratio Dlameter (um) Examples
Particle - 1-4 1-25 SiC, A;0, WC, TiC, BN, BC
Short fiber or whisker
10-1.000 0.1-25 SiC, A;0,, Al;0, + SiO%, C
Continuous fiber
> 1,000 3-150 SIC, AbO3, Al;03 +SiO;C, B, W, NbTi, NbSn
R5 PARTICLE REINFORCED MMCS
. orIn less
particle reinforced MMCS, we use very small particles having very less aspect ratio (L/D ratio) say, L/D ratio of 1, 2, 3
than 5.

These small particles are dispersed inside the matrix, So. these composites are called particulate reinforce metal matrix
composite.
(a) Short Fibers or Whiskers Reinforced MMCs
. Short fibers have a slightly higher aspect ratio or whiskers can be
used.
. Fibers can be made out of glass or ceramic materials. So, it is dispersed inside the metal matrix.
b) Continuous Fibers or Sheet Reinforced MMCS
These fibers have high aspect ratio. A continuous fiber of glass or glass fiber mat can be used.
In case of sheet reinforcement, the metal will be taken to liquid state and then brought to solid state. Reinforcement is
sandwiched to get a composite.
. Continuous fibers are found in high strength applications.
B.6 EFFECT OF REINFORCEMENTS IN METAL MATRIX COMPOSITES
" Reinforcing materials play vital role in the strengthening of the mechanical properties of metal matrix composites.
" The inclusion of various reinforcements into the metal matrix enhances the strength, hardness, stiffness and reduces
the wear and density of the materials.
" Reinforcements can be Alumina, Zirconia, SiC, Cubic Boron Nitride, etc.
For example : Aluminum reinforced with silicon carbide composites are extensively used in automobile industries and
aerospaceowing to their favorable microstructure and improved mechanical behaviour with respect to pure Aluminium but
at a lower cost. Aluminium is remarkable for the low density and its ability to resist corrosion.
The addition of SiC reinforcement in the aluminum matrix increases the hardness and ultimate tensile strenath aradually

trom 23 HV to 47 HV and 84 MPa to 130 MPa respectively.

3.7 VOLUME FRACTION
Fiber volume ratio, or fiber volume fraction, is the percentage of fiber volume in the entire volume of a fiber-reinforced
composite material.
This is very important from the point that the most of the micromechanics based approaches use these fractions,
along with the properties of individual phases, to express the properties of the equivalent homogeneous material.
In the present case, the effective properties of a composite are obtained with the assumption that the fibre is
orthotropic or transversely isotropic and matrix is isotropic in behaviour. However, with appropriate changes, fibre can
also be considered to be isotropic. In the following, the subscripts or superscripts ( and (m) will denote fibre and
matrix, respectively.
The fibre volume fraction is defined as the ratio of fibre volume to composite volume and matrix
volume fraction is
defined as the ratio of matrix volume fraction to composite volume. Let, v, v be the volume occupied by fibres and
matrix, respectively. Let, v, be the composite volume. We know that,
V+ Vm = V
 METAL AATRIX COMPO
COMPOsITE MATERIALS (3.8)

Thus, from these two definitions of volumne fractions, we can write

Fiber volume Matrix volume
Total volume Total volume
V Vm
= 1
V. v,
Thus, in notations

where. V denotes the fibre Vy+ Vmand= vm

volume fraction 1 denotes the matrix volume fraction. Note that "total yolune t

"composite volume" are used interchangeably.

Note: If the interphase is also present as a third phase then, Equation is moditied as
Fiber volume Matrix volume Interphase volume
Total volume Total volume Total volume
or V+ Vm + V, 1

Where, V,=,denotes the interphase volume fraction and v, denotes the interphase volume.

In case, there are voids present in composite, then the above equation becomes as
Fiber volume Matrix volume Interphase volume Void volume =1
Total volume Total volume Total volume Total volume

or V+ Vm + V+ V, = 1

where, V,, denotes the void volume fraction and , denotes the void volume.
38 RULE OF MITURES
Ageneral rule of mixtures is a weighted mean used to predict various properties of a composite material. It provides:
theoretical upper and lower bound on properties such as the elastic modulus, mass density, ultimate tensile strengt
thermal conductivity, and electrical conductivity.
The rule of mixtures approach is a useful method in determining the engineering and physical properties of plies ini
laminate. It is based on knowledge of the properties and volume of fibers and resin that make up a ply. The princpa
term used in the rule of mixtures approach is the fiber-volume fraction or fiber-volume ratio VA.
The total expression is:
V, + Vm t V, = 1
Where
V, = fiber-volume ratio, which is the physical volume of fibers to the total plv volume
Vm=matrix or resin-volume ratio
V= void yolume ratio, which is the volume of voids and porosity as a result of the process used
Prediction of strength of an MMC is more complicated than the prediction of modulus. This is so because there can
direct and indirect strengthening. The direct strengthening considers the contribution of fiber and the metal matr
without taking into account and strength contribution stemming trom any microstructural
changes in the metal
direct strengthening is described as follows.
The
Consider an aligned fiber reinforced metal matrix composite under a load Pc in the direction of the
s
Thisload
matrix. fibers.
distributed between the fiber and the
Thus,
P. = PmVm + PV
 cOMPOsITE MATERIALS METAL MATRIX cOMPOSITE
(3.9
where Pm and P are the loads on the matrix and the
fiber, and V. and V, are the volume fractions of the matrix and the
ber, respectively Ihis equation can be converted to tho followina alo-of-mixtures relationship
under condiions Or
ctr ain (ie. the stran n the iber,
matrix, and composite is the same):

where o is the stress, V Is the volume fraction. and the suhscrintsr f and m denote the composite, fiber, and mar
respectively. This equation, commonly referred to as the Rule-of-Mixtures, says that the strength of the
lume weighted composite so
average ofthe strengths of the fiber and the matri.
B9 PROCESSING OF METAL MATRIX
COMPoSITES
Metal Matrix Composite materials can be
produced by many different techniques.
The TocuS OT the selection of suitable process engineering is the desired kind, quantity and
reinforcement components (fibers and particles), the matrix alloy and the distribution of
application.
.By altering the manufacturing method, the processing and the
finishing, as well as by the form of reintorcement
components, it is possible to obtain different characteristic profiles.
Processing Methods:

Liquid-state Stir casting

In site processes Infiltration

Processing
method

osion
Sinter-forging

Solid-state Diffusion
bonding
Fig. 3.8
3.9.1 Liquid State Processes

" Metals with melting temperatures that are not too high, such as aluminum, can be incorporated easily as a matrix by
liquid route.
" Liquid state fabrication of MMCs involves incorporation of dispersed phase into molten matrix metal.
" In order to provide a 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 of metal matrix composites :
Gas pressure
Stir casting infiltration
Squeeze casting
Infiltration
infiltration
+Pressure die
intiltration

Fig. 3.9
 METAL MATRIX COMPOST
COMPOSITE MATERIALS (3.10)
1. Stir Casting
mabo
It is not easy to
Casting, or liquid infiltration, involves infiltration of a fiber bundle by liquid metal.
simple liquid-phase infiltration, mainly because of difficulties with wetting of
ceramic reinforcement by
the MMCs
metal. When the infiltration of a fiber preform occurs readily, reactions between the
fiber and the molten metamoll te
significantly degrade fiber properties.
Stir casting is a liquid state method of composite materials fabrication, in which a dispersed phase (ceramic materi

or short fibers) is mixed with a molten matriy metal by means of mechanical stirrng
Stir castng is the simplest and the most cost effective method of liquid state tabncoue

Electrical motor

Stirrer screw

-Reinforcement

Furnace

Crucible

Rotor
Liquid metal

Fig. 3.10
. In this technique,crucible is filled with a metal alloy which heats the alloy to the molten state. It can be
Aluminium
Copper, Titanium, Cobalt, etc. Once it is melted, stirrer is used for stirring and uniformly
the metal. Now, reinforcement is dispersed into the distribute in the heat amongs
molten metal. We can also use a of twocombination three
reinforcement mixed.
Now, inside the molten metal and even after dispersing, then the
function is first to maintain uniform heat in the stirrer is still kept continuing. So, the stirrer bas.
molten state and then, when there is a
happening, this disperse particles should be
uniformly disbursement of ceramik
So, this
process is called as stir casting process and distributed such that it gets very high mechanical
propertis
want, yOU take this mixed one and pour it inside a after
this stir casting, if you want you
allow it to solidify, t yo
mold or insider a die to get a reguired outout
Stir Casting is Characterized by Following Features:
Content of dispersed phase is limited (usually not
more than 30 volume %)
Distribution of dispersed phase throughout the matrix is not
dispersed particles (fibers). perfectly homogenous; there are local clusters o

There may be gravity segregation of the dispersed phase due to

The technology is relatively simple and low cost. difference in densities of matrix phase
dispersed and
2. Squeeze Casting
" Squeeze casting is forced infiltration method of. liquid phase fabrication
for applying pressure on the molten metal and forcing of
MMCs. using a part(ram
the lower fixed mould part.
it to
penetrate into a performed movable mouldplacedirt
dispersed phase
COMPOSITE MATERIALS
(3.11) METAL MATRIX COMPOSITE
Aporous iber preform is inserted into the die Molten metal (Aluminum) is poured into the preheated die located on
the bed of a hyarauic press. The applied pressure (70-100 MPa) makes the
preformand bond the fibers. molten aluminum penevoe e
The process is
conducted in the controlled pressure vessel and rather high fiber volume fractions:
complex-shaped structures are obtainable environment of a pres

Pouring
Pressurization Solidification Ejection
(a)

Upper movable
mould half

Molten metal

Lower fixed Preform

mould half

Ejector pin
Metal matrix composite

Fig. 3.11: Squeeze Casting

" The technique involves melting the matrix alloy in a crucible in vacuum, while the fibrous preform is heated separately.
The molten matrix material (at about 100C above the Tm) is poured onto the fibers, and argon gas is introduced
simultaneously. Argon gas pressure forces the melt to infiltrate the preform. The melt generally contains additives to
aid in wetting the fibers.
3.9.2 Spray Forming
Spray-forming of particulate MMCs involves the use of spray techniques that have been used for some time to
produce monolithic alloys.
Aspray qun is used to atomize a molten aluminum alloy matrix, Ceramic particles, such as silicon carbide, are injected
into this stream. Usually, the ceramic particles are preheated to dry them. Figure shows a schematic of this process.
An optimum particle size is required for an efficient transter. Whiskers, for example, are too fine to be transferred. The
preform produced in this way is generally quite porous. The sprayed metal matrix composite is subjected to scalping,
consolidation, and secondary finishing processes, thus making it a wrought material.
The process is totally computer-controlled and quite fast.
. Agreat advantage of the process is the flexibility that it affords in making different types of composites. For example,
one can make in itu laminates using two sprayers or one can have selective reinforcement. This process, however, is
quite expensive, mainly becaUse of the high cost of the capital equipment.
 METAL MATRIX COMPOR
cOMPOsITE MATERIALS (3.12)

Induction healed
ladle

Particle
iniector

Atomizer
(nitrogen)
Round, spray
deposited billet

Spray
chamber

Exhaust

Fig. 3.12: Spray Forming

3.9.3 Liquid Infiltration
Infiltration is a liquid state method of composite materials fabrication, in which a preformed dispersed phase (cera
particles, fibers, woven) is soaked in a molten matrix metal, which fills the space between the dispersed pha
inclusions.
The motive force of an infiltration process may be either capillary force
the dispersed phase (spontaneo
infiltration) or an external pressure (gaseous, mechanical, electromagnetic, centrifugal or ultrasonic) applied to t
liquid matrix phase (forced infiltration).
ThermocOuple. Inert gas

Molten metal
Furnac

Preform, Water jacket

Vacuumn pump
Pressure gauge

Fig. 3.13: Liquid

Infiltration
Iofltration is one of the methoS OprePalduon Or tungsten-copper compositee
 cOMPOSsITE MATERIALS METAL MATRIX COMPOSITE
(3.13)

The Principal Steps of the Technology are as Followes

.Tungsten Powder preparation with average particle size of about 1-5
mm.
, Ootional step: Coating the powder with nickel. Total nickel content is about
0.04%.
: Mixing the tungsten powder with a polymer binder.
4 Compacting the powder by a molding method (Metal injection molding, die pressing, lsostatic pressing). Compac
should provide the predetermined porosity level (apparent density) of the tungsten structure.
Solvent de-binding.
6 Sintering the green compact at 2200-2400°F (1204-1315°C) in Hydrogen atmosphere for 2 hrs.
7 Placing the sintered part on a copper plate (powder) in the infiltration/sintering furnace.
8 Infitration of the sintered tungsten porous structure with copper at 2100-2300°F (110-126°C) in either hydrogen
atmosphere or vacuum for 1 hour,
Solid State Processes:

Solid state fabrication of Metal Matrix Composites is the proces, 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. and pressing, Drawing or
Extrusion. The deformation operation may be either cold (below the recrystallization temperature) or hot (above the
recrystallization temperature).
" Deforrmation of sintered composite materials with dispersed phase in form of short fibers results in a preferred
orientation of the fibers and anisotropy of the material properties (enhanced strength along the fibers orientation).
There are two principal groups of solid state fabrication of Metal Matrix Composites:
1. Diffusion bonding
2. Sintering
3.9.4 Diffusion Bonding

" Diffusion Bonding 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).
Pressure

Melal foil

Fibers

Fig. 3.14: Diffusion Bonding

 METAL MATRIX cOMPO
COMPOsITE MATERIALS (3.14)

Spaced
foils

Spaced <
filaments

Mechanism
Fig. 3.15: Diffusion Bonding
Variants of Diffusion Bonding are Roll Bonding and Wire/Fiber Winding Steel and alur
Bonding is a process of combined roling hot or cold) strips of two different, metals (e.g.
Koll
with a metallurgical bonding between tne two layere
alloy) resulted in formation of a laminated composite material followeds
continuous ceramic fibers and metalic wires
Wire/titber Winding is a process of combined winding
pressing at elevated temperature.
Advantages and Disadvantages of Diffusion Bonding:
solid-state welding technique.
Whilediffusion bonding has many advantages, there are a few downfalls to the
Advantages
base material. The bonded surtan
The bonded materials show the same phvsical and mechanical characteristics as the
can be tested through a tensile testing.
Joints created by diffusion bonding are clean, of high quality, and free from discontinuity and porosity.
Diffusion bonding allows joining similar and dissimilar materials. For this reason, it is widely applicable.
Due to a good dimension tolerance, diffusion bonding is used to produce high precision components and comcle

shapes.
The running costs are rather low and the process is easy to approach.
Plastic deformation can be reduced under diffusion.
Disadvantages
Although the running costs are low, the initial setup cost is high.
Compared to other welding techniques, diffusion bonding is very time-consuming.
The preparation of the workpieces is critical and may be difficult.
The available equipment limits the size of the weld.

Diffusion bonding is not applicable for mass production.

The outcome is highly dependent on the welding parameters, such as temperature, pressure, metal surface finis
the welding materia.
Vacuum bot pressing is a most important step in the diffusion bonding processes for metal matriy
composites. The t
advantages of this technique are: the ability to procesS a wide variety of matrix metals and control of fiber orientation 3
volume fraction.
Among the Disadvantages are:
e Processing times of several hours.
presSures
High processing temperatures and
All of which make the process quite expensiVe
Besides the fact only objects or limited size can be produced
 COMPOSITE MATERIALS
(3.15) METAL MATRIX COMPOSITE
3.9.5 Powder Metallurgy Process (Sintering)
Gintering fabricaton of Metal Matrix Composites is a nrocess in which a nowder of a matrix metal is mixed witn a powoer
of dispersed phase ln Tom of particles or short fibers for subseguent compacting and sintering in solid state (somednes
with some presence of liquid).

8-8-3
Powder
particles
Pores

Fig. 3.16:Sintering
" Sintering is the method involving consolidation of powder arains by heating the "green' compact part to a hign
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.

The primary driving force for sintering is not the fusion of material, but formation and growth of bonds between the
particles.
There are the 3 processes which are done under sintering for metal matrix composite making.

1. Hot Pressing Fabrication of Metal Matrix Composites

. Hot Pressing Fabrication of Metal Matrix Composites sintering under a unidirectional pressure applied by a hot press.
Die fill slage Hot pressing slage

k-Upper
punch

Powder Pressed
part

LOwer
Hot die
punch

Part ejection

Fig. 3.17: Hot Pressing

 METAL MATRIX COMPO
cOMPOsITE MATERIALS (3.16)

Z. Hot Isostatic Pressing (HIP) Fabrication of Metal Matrix Composites pressure applied
Hot Isostatic Composites sintering under a from mu,
Pressing
directions through Fabrication
a liquid or gaseous mediumMatrix
of Metal surrounding the compacted part and at elevated ternperature,

Pressure

Pressurized
gas (argon)

Pressed part

Steel can
container

-Heated
chamber

Fig. 3.18 : Hot Isostatic Pressing (HIP)

contained inside the can. With HIP, it is relat
In HlP, gas pressure against a can consolidates the composite piece
easy to apply high pressures at elevated temperatures over variable geometries.
3. Hot Powder Extrusion Fabrication of Metal Matrix Composites
Hot Powder Extrusion Fabrication of Metal Matrix Composites sintering under a pressure applied by an extruder :
elevated temperature.

Direct
extrusion
Die
Billet Ram

Extruded product

Container

Indirect
extrusion

Fig. 3.19: Hot Powder Extrusion

As a solid-state process, powder metallurgy nas a lot of advantages including the following itome:
Near-net shape parts are commonly produced by PM
Aronsiderable weight fraction of the nanoparticles can also be inteqrated.
OM Can be used in batch production systems such as automotive industries
materials have been used as matrix or Compos
A wide variety of
reinforcing agent in order to produce different Nano
based on Powder Metallurgy.
 cOMPOSITE MATERIALS METAL MATRIX COMPOSITE
(3.17)

G10 IN-SITU FABRICATION OF METAL MATRIX COMPOSITES

the natriz as
In situ
fabrication of Metal Matrix Composite is a process, in which dispersed (reinforcing) phase is formed in
aresult of precipitation from the melt during its cooling and Solidification.

piferent Types of Metal Matrix Composites may be Prepared by in Situ Fabrication Method:
form of particles.
1. Particulate in Situ MMC: Particulate composite reinforced by in situ synthesized dispersed phase in

Examples: Aluminum matrix reinforced by titanium boride TiB2) particles, magnesium matrix reinforced by Mgz
particles.

2. Short-Fiber Reinforced in Situ MMC: Short-fiber composite reinforced by in situ synthesized dispersed pnse m
form of short fibers or whiskers (single crystals grown in form of short fibers).

Examples: (a) Titarium matrix reinforced by titanium boride (TiB2) whiskers,

(b) Aluminum matrix reinforced by titanium aluminide (TiAI3) whiskers.

3. Long-Fiber Reinforced in Situ MMC : Long-fiber composite reinforced by in situ synthesized dispersed phase in torm
of continuOus fibers.
Example: Nickel-aluminum (NiA) matrix reinforced by long continuous fibers of Mo (NiA-9Mo alloy).
Dispersed phases of in situ fabricated Metal Matrix Composites may consist of intermetalic compounds, carbides, borides,
oxides, one of eutectic ingredients.
Advantages of in situ Metal Matrix Composites
. In situ synthesized particdes 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:
" Unidirectional solidification of a eutectic alloy (alloy of eutectic composition) may result in formation of eutectic
structure, in which one of the components has a form of long continuOus filaments.

" Scheme of adevice for unidirectional solidification of in situ Metal Matrix Composite is shown in the figure:
" Crucible with aeutectic alloy moves downwards (or alternatively the induction coil moves upwards). This movement
results in Remelting followed by re-solidification of the alloy under controlled cooling conditions.
Value of heat transfer through the crucible bottom together with the crucible speed (v) and the power of the heating
elements (induction coil) determine particular temperature gradient, which provides unidirectional solidification with
flat solidification front.
" The allov acauires eutectic structure directed along the solidification direction with eutectic components in form of
long mono-crystals (fibers).
 METAL MATRIX COMPOR
COMPOsITE MATERIALS (3.18)

Initial alloy in
solid state

oooo o
Static
induction coil
ooo Molten alloy

Unidirectionally
solidified MMC

Direction of
the crucible
movement
Fig. 3.20: In-situ fabrication of MMC
Interfaces in Metal Matrix Composites:

The interface region in any composite is very important in determining the ultimate properties of the composite.
Most often, the ceramic reinforcement is rejected by the molten metal because of non-wettability or high conta:
angle. Sometimes the contact angle ofa liquid drop on a solid substrate can be decreased by increasing the sufa
energy of the solid or by decreasing the energy of the interface between the liquid and the solid. Thus, under certa
circumstances, the wettability of a solid ceramic by a molten metal can be improved by making a small alloy additir
to the matrix composition.
An example of this is the addition of lithium to aluminum to improve the wettability in the alumina fiber/aluminur
composite.

However, in addition to wettability, there are other important factors such as chemical, mechanical, thermal, art
structural ones that affect the nature of bonding between reinforcement and matrix. As it happens, these fadto
frequently overlap, and it may not always be possible to isolate these effects.
Major Discontinuities at Interfaces in MMCs
The important parameters that can show discontinuities in MMCs at a ceramic reinforcement/metal matrix interface are

follows:
Ronding : A ceramic reinforcement will have an Ionic ora mixed ionic/covalent bonding, while the metal matri
have a metallic bonding.
Crystallography: The crystal structure and the lattice parameter of the matrix and the reinforcement will be diterent
. . . t , To aeneral, the elastic moduli ot the matrix and the reinforcement will be different
matrix and the
Chemical potential: The reinforcement
reaction
will not be in
thermodynamic equilibrium at
at the
ioterface l
chemical
there will be a driving force for a
Coefficient of thermal Expansion (CTE)::The matrix and the reinforcement will, in general, have different CTEs.
 COMPOSITE MATERIALS
METAL MATRIX COMPOSITE
(3.19)
B11 MEASUREMENT OF INTERFACE PROPERTIES
Interfaces play a slgniticant role in determination of the nhysical and mechanical properties Of tne conpa
ohysical properties include coefficient of thermal epypansion. thermal conductivity and damping.
Coeficient of thermal expansion is an important criterion for the desian of dimensionally stable composte
Interfaces with reaction products or precipitates are likely to act as stronger bariers to heat conductivity than cleaner
ones.

" Even t thnere are no reaction products at the interface and the matrix, particle sizes and shapes are the same, the yield
strength, modulus and tensile ductility vary based on the nature of chemical bond.
. The resistance of the interface to cracking even at high strains in the surrounding matrix is also essential ror a
significant role in load transfer. Abrittle interface will crack at lower strains leading to little load transter.

" The variables controlling the characteristics of interfaces are quite large in number, such as processing (technique,
temperature, etc.) as well as composition and chemical nature of matrix and reinforcement.
" Processing variables can be manipulated to enhance the wetting between matrix and reinforcement, like addition of
alloying elements, pretreatment or coating of reinforcements, increase of temperature of molten metal, hot pressing
the blended metal and ceramic powders above solidus temperature, etc.
Ageing of the matrix with high solid solubility also affects the interface structure and chemistry.
" The chemical bond at the interface can be through a chemical reaction or electronic. The former is detrimental as it
leads to a brittle reaction product at the interface, whereas the latter is desirable.
" For electronic bonding, intimate contact between the atoms of the matrix and of the ceramic phase is necessary and
this is found more easily in the in situ composites. That is the reason some matrix-particle interfaces in XD composites
are semi coherent and improvement in Young's modulus values are higher than those seen in composites prepared by
conventional processes.
" Factors responsible for enhancement of interfacial bonding in metal/ceramic systems are:
> Presence of densely packed planes parallel to interface in either or both the reinforcement and the matrix phases.
> Presence of charged defects close to interface,
> Sub stoichiometric composition of the reinforcement, and
> Lower heat of formation of the reinforcements.
" Variety of reinforcements, the ones having metallic character form metallic bonds with the metal matrix. In such cases,
the matrix-reinforcement interfacial bonding is stronger than in other metal-ceramic composites and this leads to a
greater improvemernt in Young's modulus, yield and ultimate tensile strength values over those of the matrix material.
" Tensile ductility is also impressive in case of metallic bonding at interfaces as they can withstand higher strains.
Hence modification of interfaces is necessary to enhance the metallic character of the bond. Because of the critical role
played by interfaces in the composites, it is necessary to plan the choice of matrix and reinforcement and processing
conditions.
EXERCISE
1. What are Metal Matrix Composites? State commonly used matrix and reinforcement materials.
2. State important characteristics of Metal Matrix Composites.
3. What are the advantages and limitations of Metal Matrix composites?
COMPOSITE MATERIALS (3.20)
AFTAL MATRIX COMb
4
Ehumerate the applications of metal matriy composites in various sectorS.
What properties reinforcements should nossess for metal matrix compostes
6. Explain classification of metal matrix composites.
Define fibre volume fraction. Derive the expression of same.
8
Derve the expression of rules of mixture with respect to strength of composite
composites?
9. What are the various liquid state
processes available for processing of metal matrix Explain stir cass
process in detail.

10. Write a short note on squeeze casting process used in processing of metal matrixX COmposites.
11. What is meant by liguid infitration? Fxplain yarious steps involved in it.
12. Explain diffusion bonding process used in solid state fabrication of MMCS.
13. State advantages and limitations of
diffusion bonding process.
14 Explain sintering process in fabrication of metal matrix
composites.
15 What is meant by In-situ fabrication of Metal Matrix Composites?
16. What are the advantages and disadvantages of In-situ fabrication of Metal Matrix Composites?
17. Write a short note on interfaces in Metal
Matrix Composites.
18. What are the major discontinuities at interfaces in MMCs? Explain each in short.