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lect 5-P1

The document discusses metal matrix composites (MMCs), highlighting their definition, history, and advantages such as high strength and toughness. It details various manufacturing methods including solid state, semi-solid state, and liquid state techniques, as well as in-situ fabrication. Additionally, it outlines applications of MMCs in industries like automotive and aerospace, while also addressing their mechanical properties, advantages, and disadvantages.

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Mahmoud Essam
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3 views

lect 5-P1

The document discusses metal matrix composites (MMCs), highlighting their definition, history, and advantages such as high strength and toughness. It details various manufacturing methods including solid state, semi-solid state, and liquid state techniques, as well as in-situ fabrication. Additionally, it outlines applications of MMCs in industries like automotive and aerospace, while also addressing their mechanical properties, advantages, and disadvantages.

Uploaded by

Mahmoud Essam
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PDF, TXT or read online on Scribd
You are on page 1/ 42

LECTURE FOUR

Manufacturing of METAL MATRIX


COMPOSITE
D. Rasha Afify
Schoubra faculty of Engineering
Banha Univerisity
INTRODUCTION
A metal matrix composite (MMC) is composite
material with at least two constituent parts, one
being a metal necessarily, the other material
may be a different metal or another material,
such as a ceramic or organic compound
History

- Initial work in late 1960s was stimulated by the


high performance needs of the aerospace
industry
- Steel-wire reinforced copper, were among the
first continuous-fiber reinforced metal composites
- Boron filament was the first high-strength, high
modulus reinforcement in MMC
WHY WE USE MMC?
▪ High strength
▪ High stiffness
▪ Toughness
▪ Density
▪ Good wear resistance
▪ Damping capacity
▪ Specific modulus
CLASSIFICATION OF MMC
monofilament is a single
filament of synthetic fiber.
Monofilament is made by melting
and mixing polymers. The
polymer mixture is then extruded
through holes, creating lines of
various thickness
COMPOSITION FIBER MATRIX
REINFORCEMENT

▪ Embedded into matrix


▪ Change physical properties, wear resistance,
friction
▪ co efficient, thermal conductivity
▪ Continuous or, discontinuous
Manufacturing and Forming
Methods
▪ Solid state methods
▪ Semi-solid state methods
▪ Liquid state methods
▪ Vapor Deposition
▪ In-situ fabrication technique
Solid state methods
1. Powder blending and consolidation
A number of secondary and finishing operations can be
applied after sintering, some of them are:

➢ Sizing: cold pressing to improve dimensional


accuracy

➢ Coining: cold pressing to press details into surface

➢ Impregnation: oil fills the pores of the part

➢ Infiltration: pores are filled with a molten metal

➢ Heat treating, plating, painting


2. Solid state methods
1. Foil diffusion bonding: layers of metal foil are
sandwich with long fibers, and then pressed
through to form a matrix
Semi-solid state methods
Semi-solid powder processing
3. Liquid state methods
1. SQUEEZE CASTINGS
SQUEEZE CASTINGS
Squeeze casting infiltration is a forced
infiltration method of liquid phase fabrication of
metal matrix composites, using a ram for
applying pressure on the molten metal and
forcing it to penetrate into a dispersed phase,
placed into the lower fixed mold part.
Infiltration method is similar to the squeeze
casting technique used for metal alloys casting.
3. Liquid state methods
2. Stir casting
METHODOLOGY FOR THE FABRICATION OF
METAL MATRIX COMPOSITE BY USING STIR
CASTING`
3. Liquid state methods
3. Pressure OR infiltration Pressure
Die Infiltration is a forced infiltration method of liquid phase fabrication of Metal
Matrix Composites, using a Die casting technology, when a preformed dispersed phase
is placed into a die which is then filled with a molten metal entering the die through as
pour and penetrating into the perform under the pressure of a movable piston. By the
analysis of various methods of liquid state fabrication of metal matrix composites and
their advantages and disadvantages. The simplest and the most cost effective method
of liquid state fabrication is Stir Casting.
3. Liquid state methods
4. Spray deposition. Molten metal is sprayed
onto a continuous fiber substrate
Spray deposition
Vapor Deposition
Vapor Deposition
THE FIBER IS PASSED THROUGH THICK CLOUD •
OF VAPORIZED METAL, COATING IT
In-situ fabrication technique
In situ fabrication of Metal Matrix Composite 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.

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.

2. 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
Scheme of a device for unidirectional solidification of in situ
Metal Matrix Composite is shown in the figure:
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 .


Crucible with an eutectic alloy moves downwards (or alternatively
the induction coil moves upwards).

This movement results in remelting followed by resolidification 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 alloy acquires eutectic structure directed along the solidification direction
with eutectic components in form of long mono-crystals (fibers).

A distance between the fibers (d) is determined by the solidification speed (v)
according to the formula:
d²~v
APPLICATIONS OF MMC
Drive shaft
Material : AlMg1SiCu+20% Al2O3P
Processing : extrusion from cast feed material
Vented passenger car brake disk
Material : G-AlSi12Mg + 20% vol. SiCp
Processing : Sand / Die casting
▪ Disk brake calliper for passenger cars
▪ Material : Aluminum alloy with nextel ceramic
fiber 610 (grade of fiber use at temp 100 C)
▪ Weight reduction : 55% cast iron compared
Partial short fibers reinforced light
metal diesel pistons
Tank armors
Material : Steel reinforced with Boron nitride
Honda has used aluminum metal matrix
composite cylinder liners in some of their
engines, including the B21A1, H22A and H23A,
F20C and F22C
Demand

▪ Low density,
▪ Mechanical compatibility,
▪ Chemical compatibility,
▪ Thermal stability,
▪ High Young’s modulus,
▪ High compression and tensile strength,
▪ Good process ability,
▪ Economic efficiency
MECHANICAL PROPERTIES OF MMC
STRENGHT OF MMC
YOUNG’S MODULUS OF MMC
Advantages
▪ Low coefficient for thermal expansion
▪ Fire resistance, wear resistance.
▪ Higher transverse stiffness , strength &
modulus
▪ No moisture absorption
▪ Higher electrical and thermal conductivities
▪ Better radiation resistance
▪ Some reinforcing fibers are inexpensive
▪ Casting is low cost and net shaped process
Disadvantages

• Some fabrication processes are complex and


• expensive
• Higher cost of some reinforcing fibers
• Relatively immature technology
• Machining difficult
• Complex fabrication methods
• Reinforcing material may reduce ductility and
• fracture toughness
• Fiber-matrix interactions at high temperature
• degrade fibers

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