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➢ Processing of MMCs
➢ Processing of PMCs
➢ Processing of CMCs

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 Metallic Matrix Composites
Matrix: Metal or alloy (usually low density non-ferrous alloys)
Reinforcements: Carbon, metallic or ceramic
Continuous reinforcements: SiC, B, Al2O3, C, refractory metals etc
Discontinuous reinforcements: SiC (w), SiC, Al2O3, TiB2 (p), short or chopped Al2O3
and C fibers.

Comparison with metallic materials

MMCs can be tailored to give improved strength, stiffness, thermal conductivity,
abrasion resistance, creep resistance or dimensional stability.
Reduction in ductility / toughness and expensive

Comparison with PMCs

Higher transverse strength and stiffness, greater shear and compressive
strength, and better high temperature capabilities

MMCs are nonflammable, do not outgas in a vacuum, and suffer lesser attack
by organic fluids such as fuels and solvents.

High electrical and thermal conductivity, and resistance to most radiations

PMCs have good specific properties and are cheaper
 Metallic Matrix Composites

MMCs for electronic packaging AMC cylinder

Discontinuously reinforced titanium
(DRTi) automotive valves

Engine with integrally cast aluminum

MMC cylinder liners
Al MMC connecting rod Aluminum MMC brake rotors
Metallic Matrix Composites
Metallic Matrix Composites
 Metallic Matrix Composites
Solid state processing
1. Diffusion Bonding
2. Powder Metallurgy

Diffusion Bonding

Bringing solid surfaces in close contact and

by the application of heat and pressure
to achieve consolidation.

Sandwiching the fiber matt between two

sheets of foil and applying heat and
pressure.

Simpler shapes, complex shapes require

further processing
Extent of undesirable interface reactions
can be negligible (solid state)

Ti, Ni, Cu, and Al reinforced with boron fibers

 Metallic Matrix Composites

Whiskers, short fibers, and particulates Metal powders

g y
Production of particulate,
discontinuous and whisker Mixing and Binding
ta ll ur
reinforced composites
m e
d e r
Canning and evacuation
o w
Cold isostatic processing
P
Hot isostatic pressing Sintering

Upto 50% reinforcements can Rolling and forging

be used but are limited to about Hot extrusion
can also be applied
25% because of damage to the
fibers and loss of toughness
Final Machining

SiC(w)-Al composites (some anisotropy is obtained during pressing)

Ti carbide and boride powders for reinforcing Ti and its alloys

 Metallic Matrix Composites

Liquid state processing of MMCs

Major barriers:
- Non-wetting of reinforcements
- Adverse matrix reinforcement reactions

Solution
- Precoating the reinforcement with an appropriate material to protect against any
reaction and to enhance wetting.
- Altering the composition of the melt to improve wetting.

Pyrolitic graphite coatings Addition of Li to the Al melt: It promotes

on SiC fibers: Enhance wetting and aid processing. Formation of
wetting, small loss in Li2O.5Al2O3 spinel at the interface with no
mechanical properties apparent degradation of properties
 Metallic Matrix Composites
Squeeze Casting / Die Casting

Production of small near net

shaped components

Pressure ranging from 100 MPa

to 700 MPa are applied for Al-
alloys.

Limitations on the size of the

components: Size of the
press
 Metallic Matrix Composites

Melt Stirring / Stir Casting

Simplest technique
Mixing of reinforcement
Casting in conventional manner
in liquid metal (stirring)
Casting alloys with wide
solidification range

Stirring at high speeds creates a high

shear rate, which tends to reduce the
viscosity of the slurry even at solid
fractions as high as 50 to 60% volume.
(20 vol% for effective dispersion)

The melt reinforcement slurry can be cast

by gravity casting, die casting, centrifugal
casting, or squeeze casting.

Stirring time, temperature, stirring rate,

casting method

Uniform mixing is difficult to achieve even with stirring (difference in density)

Mixing in two phase region improves uniformity Rheocasting Compocasting

 Metallic Matrix Composites
Liquid Melt Infiltration Removal of the problem of size

- Rapid process.
-Lesser damage to
the fibers.
- Expensive fiber
coatings may not be
required.

Wide variety of fibers

e.g., SiC, C, B, Al2O3
etc can be used. Gas Pressure is maintained for the
short period of time required for
solidification.
 Metallic Matrix Composites
Deposition
• Atomization of the melt
• Introduction of reinforcements in
the path of the spray
• Deposition on a substrate.
High rate of metal deposition (0.2 – 2
Kg/sec)

Characteristics and Advantages

• Quick solidification
• Strong interfacial bond
• Fine microstructure

•Porosity ~ 5%
• High vol. fraction of reinforcements can be used

Mainly used for SiC(p) reinforcement of Al

and its alloys

May require some secondary processing

 Metallic Matrix Composites
Deposition

Arc Spray Forming

 Metallic Matrix Composites
Deposition

Electrodeposition
Ceramic Matrix Composites
 Ceramic Matrix Composites

Ceramics are brittle → Fail in a catastrophic manner (low toughness)

→ Production of CMCs to improve toughness (Strength is also normally improved)

1) Monolithic ceramic fails in catastrophic

manner.

2) Particle reinforced ceramic matrix

composite also fails in catastrophic manner
but the toughness has increased.

3) Whereas in case of fiber reinforced

ceramic matrix composite,
a substantial load carrying capacity is also
maintained even after the failure has
commenced (continuous fibers). So this
system not only has better toughness, but
also favorable failure mode (failure is not
catastrophic).

As compared to particulates, fibers are:

(a) more costly
(b) complex processing
 Ceramic Matrix Composites
Lag in the development of CMCs
➢ Processing at high temperatures (requires reinforcements that are stable at
high temperatures)

➢ Differences in the coefficients of thermal expansion α of reinforcements and

the matrices → Thermal Stresses
These thermal stresses are
accommodated by plastic deformation
in case of MMCs.

But in case of CMCs there is no

possibility of plastic deformation,
instead a catastrophic failure.

Thermal expansions of
reinforcements and the matrices
must be matching
 Ceramic Matrix Composites

Applications for ceramic-matrix composites (CMCs) fall into four major categories
• Cutting tool inserts
•· Wear-resistant parts
•· Aerospace and military applications
•·Other industrial applications, including
engines and energy-related applications

Cutting tool inserts Heat exchanger and furnace components

made from an Al2O3-SiC(p) composite.
Al2O3 – TiC
Al2O3 – SiC
Al2O3 – ZrO2
Si3N4
SiAlON

Microstructure of SiC whisker-

reinforced Al2O3 composite.
2100x

Wear Resistant Composite

ZrO2-Al2O3 ZTA
 Ceramic Matrix Composites

Space Shuttle
Ceramic Matrix Composites

Processing
 Ceramic Matrix Composites
Ceramics → Complex crystalline structures
Processing → cold pressing & sintering, hot pressing, isostatic pressing (CIP & HIP), slip casting.
Microstructure consists of randomly oriented equiaxed grains → Isotropic

Processing

1
Conventional Mixing + Pressing
2
Slurry Techniques
3
Liquid state processing

4
Sol-Gel Processing

5
Lanxide Process
 Ceramic Matrix Composites

1
Conventional Mixing + Pressing

Consolidation
Compaction & sintering, Hot pressing, CIP, HIP.

SiC whiskers in Al2O3 or Si3N4 matrices for cutting tool inserts and other wear
resistant applications.
 Ceramic Matrix Composites
2
Slurry Techniques

Short fibre reinforcements

Difficulties in conventional mixing → slurry is prepared

Agitation improves dispersion (ultrasonic or stirring)

The slurry typically consists of the matrix powder, a

carrier liquid (water or alcohol), reinforcements and an
organic binder.

Slurry/Slip casting to produce shapes (low strength &

porosity a problem).
Limited to particulates, whiskers and short fibers.
Not suitable for high performance composites.
 Ceramic Matrix Composites
2
Slurry Techniques

Continuous fibre reinforcements

Advantages
- Fairly uniform distribution of fibers
- Low porosity
- Relatively high strength
 Ceramic Matrix Composites
3
Liquid state processing
For CMCs difficulties arise
(i) Reaction due to high temperature.
(ii) Low infiltration rates due to high
viscosities.

Glass matrix and glass ceramic

composites

Permits fabrication of tubular

components

Matrix Transfer Moulding

 Ceramic Matrix Composites
4
Sol-Gel Processing A metal alkoxide, acetate, or halide is reacted to form a sol

A sol is dispersion of small particles of less than 100 nm which is usually

obtained by the precipitation resulting from a reaction in solution.
ZrOCl2 + NH3 + 3H2O = 2NH4Cl + Zr(OH)4
A gel is a sol that has lost some liquid and has an increased viscosity

The sol is converted to a gel, which in turn is subjected to controlled heating to

produce the desired end product.
 Ceramic Matrix Composites
5
Lanxide Process
It involves the formation of a ceramic matrix by the reaction between a molten metal
and a gas. Growth of the ceramic occurs outwards from the original metal surface
and through the preform.

Growth rate controlled by the rate of chemical

reaction not the transport of reacting species.

γSV > 2γSL Quick transport of liquid metal

along the channels in the ceramic matrix.

Reinforcements do not react with the gas 5 – 30% unreacted

and are wetted by the ceramic. metal

Liquid Al and Si are corrosive.

Dual BN-SiC coating by using a gaseous

phase is applied to the fibers.

BN- crack deflection, SiC- diffusion barrier.

Al2O3, SiC, and AlN
matrices can be generated.
Polymer Matrix Composites
 Polymeric Matrix Composites

Advantages

• Lighter than metals and ceramics

• Does not requires high pressures and temperatures for processing.
• Processing equipment simple and less costly.
• Polymeric material normally cheap and available.

Disadvantages

• Low working temperature.

• High coefficients of thermal expansion
• Sensitive to radiation and moisture.
 Polymeric Matrix Composites

GLARE is a fiber metal laminate (FML) composed of

several very thin layers of metal (usually aluminium) interspersed with layers of glass-fiber pre-preg

Composite applications on Airbus A380

 Polymeric Matrix Composites

All composite Voyager aircraft.

Wind tunnel blade made of carbon fiber/epoxy

skins over syntactic foam core (left) weighs 50%
less than aluminum counterpart.
 Polymeric Matrix Composites

Processing
Open mould processes Hand lay-up and spray-up processes

Common resins
Epoxy & Polyester
(usually at RT)
Prime Considerations
- Viscosity of the resin
- Process time
Hand lay-up
Applications
•· Boat hulls and decks
•· Tanks and vessels
•Wind turbine blades
•· Components for the transport industry
•· Industrial parts
•· Building parts
•· Electrical parts and covers
 Polymeric Matrix Composites

Open mould processes Handlayup and sprayup processes

Hand lay-up
Process advantages Disadvantages

• Regarded as a simple process • Low to medium number of parts/year

•Freedom of design • Long cycle times per molding
•Low mold and/or tooling costs • Labor intensive
• Low start-up costs • Operator-skill dependent
• Low to medium capital costs • Evaporation, exposure, and emission of
volatile organic compounds (VOCs)
•High-strength large parts possible
• Not the cleanest application process
• Large-sized parts possible
•Difficulty in removing trapped air
• On-site production possible
• Shrinkage during curing
 Polymeric Matrix Composites

Spray lay-up Reinforced plastic mold, spray gun, reinforcement mixer

Rolling required to remove entrapped air and surface

finish

Advantages
- Greater production rate.
- Complex shapes and geometry
- Uniform thickness

Disadvantages
- Reinforcements with continuous fibers not possible.
- Excessive fogging and bounce back
- Excessive use of resin

A typical chopped-fiber/resin laminate thickness between

consolidations is 1.5 to 2 mm
 Polymeric Matrix Composites

Vacuum Bagging extension of the wet lay-up processes..!

The pressure is applied to the laminate once laid-up in order to improve its
consolidation. This is achieved by sealing a plastic film over the wet laid-up laminate
and onto the tool.
The air under the bag is extracted by a vacuum
pump and thus up to 1 atm pressure can be applied
to the laminate to consolidate it

Advantages
- Higher fibre content laminates can be achieved than standard wet
lay-up techniques.
- Lower void contents are achieved than with wet lay-up.
- Better fibre wet-out due to pressure and resin flow throughout
structural fibres.

Disadvantages
- The extra process adds cost both in labour and in disposable
bagging materials.
- A higher level of skill is required by the operators.
- Mixing and control of resin content still largely determined by
operator skill.
 Polymeric Matrix Composites

Vacuum Bagging extension of the wet lay-up processes..!

 Polymeric Matrix Composites

Pultrusion Process

Road and rail transportation, construction,

infrastructure, marine, corrosion-resistant
equipment, electrical/electronic, consumer,
appliances/business equipment, aircraft,
and specialty.

https://www.youtube.com/watch?v=4MoHNZB5b_Y 37
 Polymeric Matrix Composites

Pultrusion Process
Continuous reinforcement
Continuous process
Resin impregnation
Production rate: Size & complexity
Heated dies (shapes & profiles)
of the section (several meters/min
can be achieved) Curing (Dies or Oven or both)

Speed: 25 mm/ min to 5 m/min

Advantages
Long lengths and large diameters
can be produced
Thin walled hollow sections
Use of widest variety of
reinforcements and resins
 Polymeric Matrix Composites

Filament Winding

https://www.youtube.com/watch?v=HPBmbkyi9Tw

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 Polymeric Matrix Composites

Filament Winding

Continuous strand of impregnated fibers, or tape

Computer controlled system
Precisely laid or wound in a predetermined manner
Manderal is withdrawn after rein is cured

The mandrel can be:

1. cylindrical,
2. spherical,
3. or any other shape as
long as it does not have
reentrant (concave)
curvature

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 Polymeric Matrix Composites

Filament Winding
Filament, wire, yarn, Glass, aramid,
tape, or other carbon fibers

High reinforcement lay down rate 50 to 350 Kg/hr

Wet Winding
Reinforcements impregnated just before winding

Dry Winding

Preimpregnated reinforcements are used

Wet winding → More flexible & cheaper

Dry winding → Cleaner process
 Polymeric Matrix Composites
Advantages
• Highly repetitive and accurate fiber placement
• The capacity to use continuous fibers over the whole
component area (without joints)
• Elimination of heating and controlled environment
• Composite with high fiber volume
• Less labour involved
• Relatively low cost of components

Disadvantages
- Mandrel can be complex or expensive
Filament wound O2 tank
- Component shape that permits mandrel removal
- Difficulty in winding reverse curvature
- Inability to change fiber path easily (in one lamina)
- Poor external surface finish

Pipe work, Pressure Vessels, Storage tanks, Helicopter blades