National Institute Of Technology, Warangal

METAL MATRIX COMPOSITE

Presented By: Raj Deep Gupta 103405 Materials Technology M.Tech (1st)

C mp site Materials
T e term c mp site i t e c mp site material sig ifies t at tw r m re materials are c mbi ed a macr sc pic scale t f rm a sef l t ird material.

INTRODUCTION
MMC(METAL MATRIX COMPOSITES)
T ese are t e materials i w ic a metallic base material is rei f rced wit typically a ceramic fibre,w isker r partic late. MMCs are differ fr m CMCs a d PMCs Differe ces exist wit respect t T e at re a d type f c stit e ts T e c s lidati a d pr cessi g appr c es. Pr perty attrib tes a d t eir liabilities.

Types of MMCs C ti s fibre rei f rced MMCs Ex- SiC fibre i Ti matrix C pped fibre rei f rced MMCs Ex- al mi a fibres i Al,Mg matrix w isker rei f rced MMCs Ex-SiC particles i Al matrix

Types

Charactersrics of MMCs
Hig specific stre gt Hig specific m d l s Impr ved wear resista ce L w c efficie t f t ermal expa si Impr ved elevated temperat re stre gt G d fatig e resista ce Impr ved dampi g capacity

T ermal Expa si

s f MMCs

Tail rability f MMCs

It is p ssible t ac ieve specific stiff ess f steel /expa si c efficie t f Be/wear resista ce f CI/dampi g capacity f C M all y i Al matrix c mp sites by appr priate selecti f matrix a d rei f rceme t.

Tali rability f Al MMCs

property UTS YS Dampi g capacity Aluminium /alloy 350 MPa 300 Mpa 1% Al MMC Up t 700 MPa Up t 680 Mpa 8%
d f r MMCs

Fatig e resista ce a d creep resista ce pr perties als g

Be efits f MMCs
1.C st be efits MMCs s bstit tes expe sive materials s c as s per all ys, Be all ys. 2.Perf rma ce be efits(pr d ctivity impr veme t) Ex- Al MMCs i raci g bicycles 3. E vir me tal be efits Ex- ca red ce ise pr d ce by a t m biles

MMC Systems
Matrix Reinforcement Type of reinforcement

Al,C ,steel,Mg, i,Ti, SiC,Al2 3,TiB2, B4C, Tita i m al mi ides Grap ite a d ickel al mi ides

Particles,s rt fibres,c ti s fibres,Hollow Sp eres a d platelets

MMCs are ma fact red bot i cast a d wroug t forms. I cast form t ese are made i to products/components and also Billets/Ingots. Currently billets up to 250 kg are manufactured. In wroug t form MMC are available in form of Extrusion,S eets and Plates.

Manufacturing Processes
Solid state processes Liquid state processes

Factors used in selection of manufacturing

1. Maintenance of reinforcement strengt 2. Minimization of reinforcement damage 3. Promotion of wetting and bonding between t e matrix and reinforcement 4. Ability to ac ieve t e spacing and orientation of reinforcement wit in matrix. 5. cost

Solid state processes

a)Powder blending and consolidation:
steps in t is process, powders of t e metallic matrix and reinforcement are first blended and fed in to mould of desired s ape. pressure is applied(cold pressing). T e compact is t en eated to temperature w ic is below melting point. Mixture can also be consolidate directly by ot pressing. T e consolidate composite is t en available for secondary processing

b) Diffusion Bonding

c)Vapour deposition:
T is procees involves continuous passage of fibre t roug a region of ig partial vapour pressure of t e metal to be deposited, w ere condensation takes place so as to produce a relatively t ick coating on t e fibre.
(vapour is produced by electron beam or p ysical vapour deposition)
ADVANTAGE wide range of alloy compositions can be used.

Liquid state processes

Dispersion process(stir casting):
T e reinforcement is incorporated in loose form in to t e metal matrix. T e simplest dispersion process in current use is t e vortex met od, w ic consist of stirring of t e liquid metal and t e addition of particles/w iskers/s ort fibers in t e vortex. Used for manufacturing of cast MMCs reinforced wit SiC, Al2 3, and ot e ceramic reinforcements

b) Spray deposition:
Stream of metal droplets impinges on a substrate in suc a way as to build up a composite. It is of 2 types 1)Droplet steam is produced by molten bat (Ex-osprey process) 2)Continuous feeding of cold metal in to a zone of rapid eat injection(t ermal spray process)

In situ fabrication tec nique

Controlled unidirectional solidification of a eutectic alloy can result in a two-p ase microstructure wit one of t e p ases, present in lamellar or fiber form, distributed in t e matrix.

Secondary Processes
Some MMCs are subjected to secondary processes for t e following purposes:: a)To eliminate porocity and enhance densification. b)To achieve fibre alignment c)To improve distribution of reinforcement

Current application of MMCs

 Aerospace  Defence  Automotive  Thermal management  Industrial

Aerospace
A)Engine components: Good creep resistance, high specific stiffness and resistance against foreign object damage are some of important requirements for aero engine components. Al & Ti matrics are currently being used for a variety of engine components. Cu MMC pump motor housing is being used because of excellent compatibility with oxygen combustion.

 B)Aerospace structures: high specific strength, high specific modulus, good elevated temperature strength and adequate fracture toughness. these attributes are required in application in application such as struts, access doors, wing, frame, stiffner and floor beam. Al MMC are used for structures.

C).Satellite and space structures: High specific stiffness, controlled thermal expansion coefficient and thermal cycling stability are the requirements. MMCs are in use in high gain antenna mast and in platform space station. Graphite fibre reinforced Mg MMCs in the form of thin walled tubes are used.

Defense applications
MMCs are used in Ground, avy, Air Deffence applications. Al MMCs used as track shoe of tanks because of 1: 30% reduction in weight compared to steel track shoe 2: better durability 3: Improved abrasion resistance

Automotive applications
MMCs reduced vehicle emmisions Increase comfort and styling options Improve fuel economy Enhanced performance MMCs are used in 1: Brake discs/brake drums 2: Cylinder liners 3: Drive shaft 4:Push rods

Industrial applications
Fly wheel for Energy storage Retainer rings for high speed motors ptical gimbal mount for an IR Missile seeker

MMCs in future technologies

MMCs are useful for high productivity, higher performance, light weight devices and cleaner environment. MMCs 1. ill enable future production for light weight mass transportation vehicles(trucks,trains) 2. ill enable manufacturing of next genration gas turbine engines having significantly improved thrust to weight ratio and reduced fuel consumption 3. ill enhance payload capacity future space vehicles

Conclusion
MMCs are only class of materials with broad range of properties and having high merit index for almost every application. MMCs have now overcome most of the technical barriers and are reaching out both high tech and mass markets .

References
^ Materials science and Engineering, an introduction. illiam D. Callister Jr, 7th Ed, iley and sons publishing Materials research:current scenario and future projection ------------Metal matrix composite by M.K.Surappa (IISc Bangalore) ^ Ratti, A.; R. Gough, M. Hoff, R. Keller, K. Kennedy, R MacGill, J. Staples (1999). "The S S RFQ Prototype Module". Particle Accelerator Conference, 1999. 2 (1): 884 886.doi:10.1109/PAC.1999.795388. ISB 0-78035573-3.