Professional Documents
Culture Documents
matrix composites
D. J. Lloyd
Introduction
The reinforcement
Materials Reviews
1994
Vol. 39
No.1
Lloyd
Cold Isostatic
Compaction
~Degassing
~~
Evaluation
Powder metallurgy
manufacturing
route
Composite manufacture
While the details of the different manufacturing routes
are often proprietary, the important features are quite
well established.
Powder metallurgy
Because of the difficulty in wetting ceramic particles'
with molten metal, the powder metallurgy route was
the first method developed. The essential features of
the powder route are shown in Fig. 1. The metal
powder is usually prealloyed atomised powder, in the
20-40 urn size range, but it can also be a blend of
elemental powders, or rapidly solidified chopped
ribbon or flake, as in the Allied-Signal process.l" As
noted previously, the blending step is important since
this establishes the initial homogeneity of the composite. Because the metal powder particles have a
hydrated oxide film, it is necessary to remove the
associated water molecules before consolidation
if
subsequent gas porosity is to be avoided. The vacuum
hot pressing consolidates the composite to over 95%
Particle
GN m-z
Density,
9 cm-3
SiC
420-450
32
Alz03
380-450
396
International
Materials Reviews
1994
Coefficient of
thermal expansion,
K-1
Specific
heat,
J kg-1 K-1
Thermal
conductivity,
Wm-1 K-1
Poisson's
ratio
4'3x10-6
70 x 10-6
840
1050
10-40,
at 11 OOC
017
at 1000C
025
Vol. 39
No.1
5-10,
Lloyd
Microstructure
of
Duralcan
606120 vol.-%AI203 composite after extrusion
Materials Reviews
1994
Vol. 39
No.1
Lloyd
C\J
I
E
z
V)
25
20
>t::: 15
(j)
u
(j)
10
5
O-+---.----r-~~~~~~~~E....J
o
3
Microstructure
of Comalco 6061-20 vol.-%
spherical oxide after extrusion
10 20 30 40 50 60 70 80 90 100
SHEAR RATE 5-1
I
Shear
rate
dependence
of
viscosity
of
A356-15 vol.-%SiC
metal processing routes to be used, and hence minimises the cost. At the present time, composite material
is available from Duralcan for about US$6/kg. It
does, however, have some problems in terms of reactivity between the reinforcement and the melt, and
particle segregation effects, both of which are considered in later sections. The volume fraction of reinforcement is also limited in the mixing method because
the viscosity of the melt increases with particle content
and becomes non-Newtonian.
The viscosity of unreinforced aluminium is about 10-3Nsm-2,'but
as
seen from Fig. 4, the viscosity of molten composites
is much larger, and shear rate dependent.F The
rheology of molten composites is poorly understood,
but appears to be history dependent." and increases
with increasing
volume fraction and decreasing
particle size. As a result, the power requirements
necessary for mixing limits the amount of reinforcement that can be used.
Semisolid casting
The microstructures developed by stirring a semisolid
melt were investigated in the early 1970s.34 The
partially
solidified,
non-dendritic
microstructure
developed has high viscosity which inhibits ceramic
particle settling and floating, and can be used to
retain particles in the melt. 35,36 This method has been
developed for magnesium alloys by the Dow Chemical
CO.37 The process is restricted to longer freezing
range alloys and, other than this, has the same
limitations as the fully liquid mixing methods.
Pressure infiltration
In this process, a packed bed of ceramic particles is
evacuated and then infiltrated by a pressurised melt
to form a 'master composite hardener' containing
about 50 vol-"
of reinforcement. This hardener can
then be diluted by adding it to an unreinforced melt,
and the reinforcement
redispersed
by submerged
mixing.Pr" However, this dispersion is quite difficult
because of the' high viscosity of the master hardener,
and it is difficult to obtain dispersion without incorporation of gas and oxide into the melt. Recently, a
bottom mixing process has been suggested, where an
International
Materials Reviews
1994
Vol. 39
NO.1
Lloyd
65G-r--------------------,
PVC Exterior
Claddll)Q
64
v
(/)~ 63
::>
Pressure Relief
Venls \
:5
a
:J
,~ ToAlr
62
61
600-+--.......----,----r---.----r---,---r---,--'
o 0.5
2
3
4
TIME AT 675C, h
ReInforced
Wall
6
5
Spray codeposition
system
+ Ti + Al ~
TiB2
+ Al
(1)
(2)
and
C
+ Ti + AI~TiC + Al
Matrix-reinforcement
reactivity
+ 3SiC~
Al4 C3
+ 3Si
. (3)
Materials Reviews
1994
Vol. 39
No.1
Lloyd
14
-t-
o'!-
13
~
~
12
1.5
11
0.08
"3
0.06
o
~
MgO
C\I
-.g
0.10
<(
CJ)
I
-ri
10
co
1.0
C\I
0.04 ~
CJ)
CJ)
.9
tf)
0.02
CJ)
2 0.5
C\I
.9
CJ)
2
L---'--4-----+--+--f----t--+---+--+--+
0.00
920 940 960 980 1000 1020 1040 1060 1080 1100 1120
TEMPERATURE, K
~oo
7
700
800
TEMPERATURE,oC
Silicon
level required
peratures
to
prevent
reaction (after Ref. 58)
at different
temaluminium
carbide
Fig. 7.58 So for processing routes involving long contact times between the reinforcement and the melt,
high silicon aluminium alloys are p~efe~red. In p~~der
processing using solid state consolidation, alum~n.tum
carbide formation is not a factor because silicon
carbide is stable below the solidus; however, if liquid
phase sintering is involved there is th~ potential for
reaction. It is the molten metal processmg routes that
are particularly prone to reaction, since the p~rticleliquid metal contact times can be long, partt.cularly
when large scale casting processes, or remelting are
involved. The spray codeposition method is the least
susceptible, since in this case the contact time is only
in the order of seconds.
Other carbides, such as boron carbide and titanium
carbide are also thermodynamically
unstable in
molten aluminium, but often react in a more complex
manner. 14
Magnesium has no stable carbide, so ceramic carbides are stable in pure magnesium. However, many
of the magnesium alloys of interest contain alloying
elements such as aluminium, which will form carbides, and in these magnesium alloys reaction may
occur if the contact times are sufficiently long.
Aluminium oxide, Al2 3, is stable in pure aluminium, but reacts with magnesium in AI- Mg alloys
3Mg+AI203~3MgO+2AI
oxides in
a(t)=---
w(t)
. (6)
WO-We
where
Wo
at t
0, w(t)
(4)
and
3Mg+4AI203~3MgAI204+2AI
. (5)
International
Materials Reviews
1994
Vol. 39
No.1
AI203
Lloyd
948 K
0973 K
0998 K
Z"0.8
1023K
1048 K
~ 1.0
+I
Q
t<{
1073K
0.6
0::
t-
~ 0.4
U
Z
00.2
U
CJ)
20.0
10
50
250
100
150
200
TIME, min
300
Ref. 59)
. (7)
w = 003
+ (wo
- 0'03)
x exp{50[exp(-I03
OOO/RT)](to
- t)}
(8)
(9)
where
C = heat capacity
d = diameter of channel
h = heat transfer coefficient
H = latent heat
Ps = density of solid, taken to be equal to density
of liquid
Tm = melt temperature
To = mould temperature
I1T= melt superheat
v = velocity of liquid.
For composites several terms will be modified. The
density, Ps, will be replaced by the density of the
composite, Pc
Pc
Pm(1-
J!;,)
+ Pp J!;,
(10)
where
Pm = density of matrix
Pp = density of particle
J!;, = volume fraction of particle.
The latent heat involved in solidification will be
reduced because the particles are not involved in the
solidification process; the effective latent heat, He' is
given by
He = H(I-
Vp).
(11)
+ Cp Wp
(12)
where
Cm = specific heat of matrix
Cp = specific heat of particle
~ = weight fraction of particle.
International
Materials Reviews
1994
Vol. 39
No.1
Lloyd
70 ~------------..,
70
A
60-
<9 40Z
t-
Eu 50-
..
:r:
t-
W
--J
a::
30-
(a)
50
100
150
200
250
a
300
a 750C; b 800C
Spiral fluidities
+ 2'5Vp + 10'05V~)
where
n; = viscosity of composite
nm = viscosity of unreinforced
. (13)
matrix.
The non-Newtonian
behaviour of molten composites
makes comparison with equation (13) difficult, but it
is expected to be of the right order at very high shear
rates, when Newtonian behaviour is approached. At
low shear rates, or when reaction occurs between the
reinforcement and the melt, it greatly underestimates
the viscosity. If extensive reaction occurs the viscosity
can, in effect, increase to infinity, and the melt will
not flow into the mould at all.As a result, rheological
factors dominate the casting fluidity under these
circumstances. This effect is demonstrated in Fig. 11,
where the spiral fluidities after different holding times
at 750 and 800C are shown. For 750C the spiral
fluidity remains about constant with holding time,
because the extent of aluminium carbide formation is
limited at this temperature
in a 7 wt-%Si alloy.
However at 800C, the amount of aluminium carbide
increases rapidly with time resulting in a marked
decrease in fluidity until, after 250 min, the composite
will not flow into the mould.
As noted previously, the rheological behaviour of
composite melts is poorly understood,
but a few
general statements can be made:
1. The viscosity is non-Newtonian, decreasing with
increasing shear rate.
International
Materials Reviews
1994
Vol. 39
No.1
(b)
I
50
10-
i
20-
(/)
10-
n;
a:
20-
(/)
11
--J
30-
<9 40Z
--J
a:
a::
E sau
--J
60-
100
1
,
...
200
250
HOLDING TIME, min
150
300
Microstructures
The most important aspect of the microstructure
is
the distribution of the reinforcing particles, and this
depends on the processing and fabrication routes
involved. However, particles can modify other aspects
of the matrix microstructure.
Lloyd
Reinforcement distribution
In powder processed material, the reinforcement distribution will depend on the blending and consolidation procedures, as well as the relative size of the
matrix and reinforcing particles. If the matrix powder
is large relative to the reinforcement, the reinforcing
particles will agglomerate in the intersticies of the
coarse particles, and be very inhomogeneously distributed in the final product. With the blending and
consolidation route used in one study.t" an AI/SiC
particle size ratio of 07: 1 gave a more uniform
distribution than a 024: 1 ratio. Any secondary processing will also tend to homogenise the particle
distribution.?" (It should be noted that quantitative
determination
of particle inhomogeneity
and clustering, considering the variable shape and size of
reinforcing particles, is not a trivial task. Initial
approaches
have used the Dirichlet
tesselation
method. 69. 70)
In composites processed by molten metal mixing
methods, the situation is somewhat more complicated
because the reinforcement distribution is influenced
'by several factors:
1. Distribution
in the liquid as a result of the
mixing.
2. Distribution in the liquid after mixing but before
solidification.
3. Redistribution as a result of solidification.
The distribution
during mixing will obviously
depend on the mixing process used, and it is essential
to produce as uniform a distribution
as possible
without any gas entrapment, since any gas bubbles
will be lined with reinforcing particles. After mixing
and before solidification, the particles will segregate
due to gravity.P With the relatively high volume
fraction of particles and a range of particle size, the
settling will be hindered 71
Jt::
Vo(l- C)P
where
C = particle concentration
d = particle diameter
D = container diameter
p = 465 + 195d/D for R, < 02
=(435+ 175d/D)R;0,03 for 02<Re<
R; = Reynolds number
Jt:: = particle velocity
Vo = Stokes velocity.
. (14)
casting;
Influence of solidification
particle distribution
b high solidification
conditions
on
Materials Reviews
1994
Vol. 39
No.1
10
Lloyd
15
14
13
12
~11
z'10
0 9
(9 7
Z
6
0
.--J
b.
3
2
b.
1
0
10
EXTRUSION
13
100
1000
RATIO
d[(1 -
t;,)/t;,J 1/3
(15)
Materials Reviews
1994
Vol. 39
No.1
Aging effects
Another aspect of the microstructure
which may be
modified in composites is that of precipitation. Many
studies of the age hardening response of metal matrix
composites have been reported87-93 and, in general,
an enhancement
of the aging kinetics has been
observed. However, some of the studies demonstrate
that at low temperatures the aging kinetics are slowed
down, or unaffected by the reinforcement,89,91,94 The
more rapid aging kinetics were initially attributed to
easy precipitation nucleation on dislocations punched
out from the reinforcement particle interface as a
result of the coefficient of thermal expansion mismatch
on quenching from the solution treatment temperature. Enhanced precipitation in the neighbourhood
of reinforcement
particles undoubtedly
occurs for
precipitates, such as 0' and S', which are susceptible
to dislocation nucleation." but there are many other
factors which may influence aging. In material processed by powder metallurgy, there are also fine oxide
particles in the matrix which are known from work
on SAP-type alloys to influence the aging kinetics."
The presence of fine oxide particles, together with a
fine grain size is likely to reduce the vacancy concentration by providing a high vacancy sink density, as
do the matrix/reinforcement
interfaces. Vacancies may
also be swept up by moving dislocations associated
Lloyd
11
130,....,----------------,
120
(\J
IE
zllO
o
~ 100
-.J
::J
o
o
2
u
~
s = 1.5h
/./:,./
90
/./
/.
/..
= 1.0
80
V>
Ljj
70
- -----
60
14
Rule of Mixtures
Equivalent Inclusion
Tsai-Halpin Equation
50
+------,r-----r----.---~---1
o
5
10
15
20
25
VOLUME, 0/0
Mechanical properties
Elastic modulus
The on~ mechanical property which is always significantly Increased by the addition of reinforcement is
the elastic modulus. The quantitative
value of the
elastic modulus is somewhat
dependent
on the
method of measurement,
with dynamic measuring
methods tending to give larger values than static
measurements
obtained from the elastic portion of
the tensile stress-strain curve. Static values may also
depend on whether the measurements
are made in
tension or compression.l''?
Most of these difficulties
15
e, = VpEp + VmEm
~here s; Em' s, are ~he elastic
(16)
=
e
Em(J + 2sqJt;,)
l-qJt;,
. (17)
where
(Ep/Em - 1)
q = (Ep/Em) + 2s
. (18)
Materials Reviews
1994
Vol. 39
No.1
12
Lloyd
100
C\I
IE
Z 90-
(/)'
:3
80-
A356
A356/SiC120p
2: 70(/)
360-
Z.250
(/)
(/)
100
l-
(/) 150
200
300
400
50
O-+---+----+--+---l'-+---+----+--+---l'-+---+----+--+--lf---l
500
600
TEMPERATURE,oC
16
1994
100 :
I-
-t----.------.-----.----.,.----.II'I---j
I
I
W200
0::
0
>50
350
IE 300
::::>
C\I
Vol. 39
No.1
17
reinforcement with an aspect ratio below that necessary for full reinforcement loading, gives the composite
strength as109
. (19)
where (J m is the yield stress of the matrix, and s the
aspect ratio.
For the aspect ratio typically used in particle
MMCs, which are in the 1-5: 1 range, equation (19)
underestimates
the strength,
but Nardone
and
Prewo '?" have suggested that better agreement is
obtained if the equation is modified to allow for end
loading effects. The difficulty with this continuum
approach is that it ignores the influence of particles
on the micromechanics
of deformation, such as the
very high work hardening at low strains, and modifications in microstructure,
such as grain size and
dislocation density.
In the micromechanics
approach,
the possible
strengthening mechanisms are:
1. Orowan strengthening.
2. Grain and substructure strengthening.
3. Quench hardening resulting from the dislocations generated to accommodate the difference in
coefficient of thermal expansion between the reinforcing particles and the matrix.
4. Work hardening, due to the strain misfit between
the elastic reinforcing particles and the plastic matrix.
The extent to which the different mechanisms operate will depend on the microstructure and processing
of the particular composite. In powder processed
composites, the grain size can be extremely small and
significantly contribute to the strength, whereas in
melt processed MMCs the grain size more closely
approaches unreinforced alloys. At typical volume
fractions, Orowan strengthening is not a major factor
with the 5 urn and larger particles usually used, but
particles of this size can result in quench hardening
and enhanced work hardening because of elastic misfit
back stress hardening.111-113 From these considerations, the strength of particle reinforced composites
is most strongly dependent on the volume fraction of
reinforcement with a somewhat weaker dependence
on particle size. lOS Normal matrix strengthening due
to solution and precipitation
hardening will give
additional strength to the composite.
Lloyd
Table 2
13
Composite*
YS,t
MN m-2
UTS,
MN m-2
Wrought
AI-M92Si
6061 /AI203/1 Op (T6)
6061/AI203/15p
(T6)
6061/AI203/20p
(T6)
6061/AI203/20p
(T6)
6061 /SiC/15p
(T6)
6061 /SiC/15p
(T4)
6061/SiC/20p
(T4)
296
317
359
305
342
405
420
338
359
379
Duralcan, Alcan
Duralcan, Alcan
Duralcan, Alcan
Comral 85, Comalco
Cospray, Alcan
70
50
98
105
DWAt
DWAt
40
115
DWAt
84
92
Duralcan, Alcan
Duralcan. Alcan
101
100
98
100
Duralcan, Alcan
Cospray, Alcan
Cospray, Alcan
630
33
23
10
20
30
5-7
2-4
116
BP~
DWAt
517
503
503
493
532
610
483
466
460
400
490
Supplier
81
87
98
85
91
460
500
515
483
476
modulus,
GN m-2
75
54
21
34
32
330
364
430
6061/SiC/25p
(T4)
AI-Cu
2014/AI203/10p
(T6)
2014/AI203/15p
(T6)
2014/ AI2 03 /20p (T6)
2014/SiC/15p
(T6)
2618/SiC/12p
(T6)
2124/SiC/178p
(T4)
2124/SiC/25p
(T4)
Elongation,
BP~
2124/SiC/20p
AI-Zn-Mg
(T4)
405
560
105
7075/SiC/15p
7049/SiC/15p
(T651)
(T6)
601
643
(T6)
735
3
2
2
95
90
105
Cospray, Alcan
Cospray, Alcan
7090/SiC/20p
AI-Li
556
598
665
8090/SiC/13p
8090/SiC/13p
8090/SiC/17p
8090/SiC/17p
(T4)
(T6)
(T4)
(T6)
455
499
310
450
520
547
460
540
4
3
4-7
3-4
101
101
Cospray, Alcan
Cospray, Alcan
103
103
BP~
BP~
20
105
XD, Martin
06
82
91
98
95
114
Duralcan,
Duralcan,
Duralcan,
Duralcan,
Duralcan,
DWAt
Cast
AI-Cu
201/TiC/20p
AI-Si
(T7)
420
356/SiC/10p
356/SiC/1 5p
356/SiC/20p
380/SiC/10p
380/SiC/20p
Mg-AI-Zn
(T61)
(T61 )
(T61)
(F)
(F)
287
329
AZ91/SiC/94p
AZ91 /SiC/151
AZ61/SiC/20p
336
245
308
308
336
357
332
356
191
208
260
236
236
328
~I British
03
04
10
04
fraction
Alcan
Alcan
Alcan
Alcan
Alcan
Dow
Dow
Dow
of particles.
Petroleum.
Table 3
Alloy
Typical unreinforced
YS,*
MN m-2
UTS,
MN m-2
310
524
470
470
6061
2014
2124
2618
(T6)
(T6)
(T6)
(T6)
275
476
7075
8090
A356
A380
(T6)
(T6)
(T6)
(F)
505
415
205
AZ61
AZ91
475
54
80
2
1
25
Marietta
325
370
160
157
168
570
485
280
320
198
311
alloy properties
Elongation,
%
20
13
12
9
10
7
6
35
30
21
Elastic
modulus,
GN m-2
69
73
72
74
72
80
76
72
38
49
Materials Reviews
1994
Vol. 39
No.1
14
Lloyd
601lJ-r---------------------,
20,u,--------------------,
C\I
18
IE 50
z
2
40
IE
16
14
,12
(/)
(/)
~ 30
~1O
0::
~ 8
(/)
..J
A356
A3561l5SiC
(/)
---
C\I
20
........- 606l1SiClfT6
(/)
--+- 6061/SiCfT4
----&- 2124/SiCfT4
W
>=10
a
..J
>=
10
15
20
25.
30
35
18
Materials Reviews
1994
Vol. 39
No.1
50
100
150
200
250
300
350
TEST TEMPERATURE. DC
19
strength is primarily controlled by the higher temperature strength of the matrix. However, a small
improvement in strength over the unreinforced alloy
is retained at higher temperatures, as shown in Fig. 19.
This figure compares the strength at temperature of
unreinforced A356 with A356/SiC/15p after a 100 h
soak at temperature. The composite has about a
10 MN m -2 higher strength than the matrix at 300C,
and the decrease in composite strength with temperature follows that of the matrix. By using powder
processing of rapidly solidified powders, improved
high temperature strengths can be achieved..i i s
Another alternative is to use a very high volume
fraction of reinforcement in a normally solidified
matrix. By going to a high volume fraction of particles
the Orowan strengthening component becomes significant, and this is essentially independent of temperature other than the temperature dependence of the
modulus. The Lanxide Corp. Primex pressureless
metal infiltration technology allows high volume fractions to be obtained in near net shapes, and Fig. 20
shows the temperature dependence of Lanxide NX,
which is essentially 3360 alloy (AI-Si) containing
60 vol._%SiC.1l6
The high temperature strength
advantage of the composite is very significant, but
there is, of course, a sacrifice in ductility.
Elongation
Lloyd
15
20
25u,-------------------,
~ 20
-.-
336/60SiC
18
-.-
ALLOY336
16
cf!.
E
z
215
o Iti um
D
7.5Jlrn
14
[]
612
(!)
~1O
0
...J
6
w
0:::
l(/)5
~1O
I-
0
D
4
2
o
100
200
300
400
500
0+----+--+---+--+--t---f--t--+---+--4--1
600
TEST TEMPERATURE,oC
20
of 336
closely spaced elastic particles would be highly constrained, resulting in local stress levels many times
the matrix flow stress. This behaviour has been confirmed by recent continuum modelling.106,122Since
ductile failure mechanisms by void nucleation and
coalescence are very sensitive to the triaxial stress
level,123fracture nucleation within particle clusters is
expected.
Many models have been developed for void
nucleation. Particle cracking by catastrophic propagation of an interal defect is given by the Griffith
equation
(Jf
(~cy)1/2
,'-
(20)
124
2
18
-+-
6061/Sicrr6
-+- 60611A~03
/rs
~1
12
~1
~
0
...J
W
2
0
10
15
VOLUME
21
20
25
50
100
TEST TEMPERATURE,
30
35
40
FRACTION, 010
22
350
IJ + 06
(J'rn
2 + 2k
. (22)
Materials Reviews
1994
Vol. 39
No.1
16
Lloyd
0.20,---------------------.
..J
U 0.18
F=
lti urn
7.5Jlrn
~ 0.16
n;
0.14
W 0.12
~ 0.10
50.08
~ 0.06
Z 0.04
o
o
~ 0.02
DOD
....
~ 0.00 +-0----G~
_ _+___+___+-l____+__+___l:jl--_+__+__+-+___+__j
60 80 100 120 140 160 180 200 220 240 260 280 300 320 340
UTS, MN m-2
23
1994
Vol. 39
No.1
Fracture toughness
The fracture toughness of particle reinforced composites has been reviewed
in two recent publications.126.127 While the toughness mirrors to some
extent the tensile elongation, decreasing with increasing reinforcement, the decrease is most significant
from zero to 100/0 reinforcement, with only a slight
decrease for higher reinforcement loadings. The fracture toughness is also much less sensitive to the degree
of aging than is the tensile elongation, and there
are some data suggesting that coarser particles are
beneficial. With typical' toughness values in the
15-20 MN m -3/2 range, it is apparent that particle
composites do provide a reasonable degree of fracture
toughness.
In the continuum mechanics approach to fracture,
the fracture toughness of a' material is normally
assessed in terms of some crack tip parameter at the
initiation of crack growth. Specifically, fracture will
occur when the crack tip strain, et, is exceeded over
some microstructurally
significant characteristic distance, 10, ahead of the crack tip. Under conditions of
small scale yielding
et = co]
. . . (23)
be
CK2 / Eay
(24)
K1C
[2ayE(n/6)1/3d]1/2j;1/6
. (25)
Lloyd
En(2nA)1/2
(26)
258(pG'yEBe)1/2
Bf,
the fracture strain, may be a reasonable
assumption.
Table 4 compares the fracture toughness predictions of equations (25) and (27) with the experimental
results of Klimowicz
and Vecchio 129 for 6061/
A1203/15p and (AI-Cu) 2014/AI203/15p.
In comparing the data the particles were assumed to be
homogeneously distributed, with a 10 urn particle size,
and the crack radius was taken as 50 urn,
As expected the Hahn and Rosenfield equation
predicts an increase in fracture toughness
with
increased aging which is contrary to experiment. The
limit load approach of Thomason correctly predicts
the general trend with aging time, but tends to
underestimate the fracture toughness, particularly for
the 2014 matrix composite. However, the extent of
agreement
does suggest that models based on
nucleation controlled fracture may be appropriate for
particle composites. In this case control of particle
volume fraction and distribution will be important
for optimum fracture toughness.
There is not much information on the influence
of temperature
on fracture
toughness,
but in
2009/SiC/20p there is a small increase between 25
and 200C, and a decline above 220C.136 A micromechanical model based on a critical strain concept
was used to predict the temperature dependence, with
the local fracture strain being inferred from tensile
data.
It is apparent from this discussion that the present
models of fracture toughness need extensive development to explain the toughness of MMCs. It is difficult
to take account of reinforcement
inhomogeneity,
particle size distribution, and any residual stresses
present in the composite, all of which are likely to
influence the fracture toughness.
Finally, it should be noted that obtaining valid
plane strain fracture toughness values for composites
can be a problem and many of the results in the
Be ~
Table 4
. (27)
17
Composite
Thomason
AI-Cu
Elongation,
Kexp,
MN m-3/2
MN m-3/2
242
217
195
254
120
124
190
181
117
156
~h'
equation
2014/AI203/15p
3 h, 160C
7 h, 160C
16 h, 160C
40 h, 160C
48 h, 160C
AI-M92Si
6061/AI203/15p
1 h, 17rC
3 h, 17rC
10 h, 17rC
25 h, 17rC
100 h, 177C
331
441
469
420
372
6
2
1
1
221
317
345
331
276
247
5
3
3
4
232
227
215
212
215
218
176
172
180
331
242
311
221
247
248
International
equation
Materials Reviews
1994
Vol. 39
No.1
18
Lloyd
280-r---=-----------------,
1O-4.-r-----------------~
260-
(\J
IE
Z 240-
D 6061/15A1203,T6
6061~T6
10-5
Q)
u
~
, 220-
(j)
(j)
~ 10-6
~ 200-
EU
t(j)
~
~
X
:J
180-
~ 10-7
160-
0% A~03
ro
"0
(/~~/
140-
15% AIz0,
10-8
~ 120-
103
1b4
105
CYCLES
24
I
I
107
1~6
1O-9-t-----r---.----,---,-r--r-.--.-----.--~"T""""""T"-_._____._J
3
5
10
20
STRESS INTENSITY
RANGE (~K), MN m-3/2
TO FAILURE
T6 at R= -1
25
6061/AI203/15p,
Materials Reviews
1994
Vol. 39
No.1
. . . . . . . . . . (28)
= -16'1-
228 . . . . .
(29)
Lloyd
. . . . . . . . (30)
19
3
= A'DL
A
b
5
(0" - 0"0)8
(31)
Commercial aspects
As noted in the introduction, particle MMCs are now
at the commercial production stage, and a whole
range of factors have to be addressed to produce a
cost competitive component. Table 5 lists the factors
involved in determining the finished component costs.
Considering that MMCs contain hard ceramic
International
or painting
Materials Reviews
1994
Vol. 39
No.1
20
Lloyd
particles, have high wear resistance and limited ductility, even the most straightforward operation, such
as sawing, can require modification of the conventional equipment. Extensive sawing and machining
studies have been carried out, and viable commercial
practices established.P"
Most applications require some degree of machining, such as sawing, milling, drilling, reaming, and
tapping. The ceramic particles present in composites
have hardnesses approaching that of the machine tool
material, which means that abrasive wear of the
tooling is the main issue. To minimise abrasive wear
the area and contact time between the tool and the
workpiece should be kept as low as possible during
the machining operation. This means that MMCs
should be machined at higher feed rates and depth of
cut than traditionally used with unreinforced Al
alloys. As an example, face milling of unreinforced Al
is typically carried out at a feed rate of around
0013 ern per tooth. Increasing this by a factor of 4
for the composite not only increases the removal rate,
but also increases tool life by a factor of 3. Low
cutting speeds, which minimise the temperature rise
during machining, also increases tool life.
The hardness of the tooling is an important factor
in controlling tool life. High speed steel tools are
dulled in seconds, while conventional and coated
carbide tooling last only a few minutes. By far, the
most cost effective tooling is polycrystalline diamond
(PCD), provided it is of high quality. Unfortunately,
PCD tooling is not yet available for taps or very
small diameter drills and reamers, so carbide tools
must be used for these operations.
The composition of the MMC, in terms of type,
shape, size, and volume fraction of reinforcement will
affect machine ability. A matrix with a soft reinforcement, such as graphite, will be easier to machine than
a matrix reinforced with Al2 3, The shape of the
reinforcement may influence the ease with which the
ceramic particles are sheared, but there is no information available on this. Increasing the reinforcement
particle size and volume fraction will increase the
abrasiveness of the composite, but the uniformity of
the reinforcement distribution will also be important.
Large clusters of ceramic particles will act as large
inclusions with regard to tool damage.
Many factors, therefore, affect the machining of
MMCs, but guidelines are being developed which will
enable MMCs to be commercially machined, see for
example, Ref. 155.
Many of the early composite extrusions used lubricated conical dies to facilitate extrusion, but this is
not commercially viable except for very simple, symmetrical shapes. Fortunately, the conventional direct
extrusion process with unlubricated shear faced dies
is feasible with appropriate die design and extrusion
practice, though speeds are lower and extrusion pressures higher.156.157Excessive die wear can be minimised by using high wear resistant inserts. However,
appropriate extrusion die material is still an area
requiring development, particularly for complex
shapes.
Directly casting to final shape, and other near net
shape processing reduces some of these production
difficulties, but a degree of final machining is necessary
1994
Vol. 39
No.1
....J
2
ffi <D
~~
25.----------------------,
AI/SiC
20
I.L X. 15
OZ
I-Q
Z(j)
~zlO
~~
I.LX
I.LW
W
u
01+-r-,__r_r_1""""T""T'""T""T""T'"
.........
"""T""'T""'1"""T"""T"""............-~..,...,_,._r_T"""T__r_r_.....,....,_T'""'T""T'"
.........
""T"""r'T_r_T""'~
10
20
30
40
50
60
70
80
90
100
26
Lloyd
21
commercial component runs, and meeting specifications with' high yields and at acceptable cost, now
become the key factors in successful exploitation. The
technologies are now available which should be able
to meet these requirements, and the next 5 years or
so will demonstrate whether particle MMCs will
become a general use engineering material, or be
limited to niche markets, which is the role they have
played to date.
Acknowledgments
The author is. grateful to Alcan International Ltd for
permission to publish, and to his colleagues at the
Alcan Research Centres in Kingston, Banbury, and
Arvida, and at Duralcan USA, San Diego and Dubuc
plants, for their contributions to the ideas and information in this article.
References
1.
2.
CHOU, A. KELLY,
and
1985,23,171-199.
A. OKURA: Composites,
1985,
16, 187-206.
3.
and w. R. SYMES:
in Proc. 5th Int. Conf. on 'Composite materials - ICCM-V',
(ed. W. C. Harrigan, Jr et al.), 671-685; 1985, Warrendale,
PA, The Metallurgical Society of AIME.
4. s. V. NAIR, J. K. TIEN, and R. C. BATES: Int. Met. Rev., 1985,
30, 275-290.
5. T. DONOMOTO, K. FUNATANI, N. MIURA, and N. MIYAKE: SAE
Technical Paper 830252, Detroit, MI, 1983.
6. M. H. STACEY: Mater. Sci. Techno!., 1988, 4, 227-230.
7. DEONATH and P. K. ROHATGI: J. Mater. Sci., 1980, 15,
2777-2784.
8. M. K. SURAPPA and P. K. ROHATGI: J. Mater. Sci., 1981,
16, 983-993.
9. A. BANERJI, M. K. SURAPPA, and P. K. ROHATGI: Metall. Trans.,
1983, 14B, 273-283.
10. B. P. KRISHNAN and P. K. ROHATGI: Met. Technol., 1984,
11, 41-44.
11. W. KAI, J. M. YANG, and w. C. HARRIGAN, Jr: Scr. Metall., 1989,
23, 1277-1281.
12. B. ROEBUCK and A. E. J. FORNO: in 'Modern developments in
powder metallurgy', Vol. 20, 451-465; 1988, Princeton, NJ,
Metal Powder Industries Federation, American Powder
Metallurgy Institute.
13. J. J. LEWANDOWSKI, C. LIU, and w. H. HUNT, Jr: in 'Processing
and properties for powder metallurgy composites', (ed.
P. Kumar et a!.), 117-137; 1987, Warrendale, PA, The Metallurgical Society of AIME.
14. D. J. LLOYD, H. P. LAGACE, and A. D. McLEOD: in 'Controlled
interphases in composite materials - ICCM-III', (ed.
R. Ishida), 359-376; 1990, London, Elsevier Applied Science.
15. D. J. LLOYD and B. CHAMBERLAIN: in 'Cast reinforced metal
composites', (ed. S. G. Fishman and A. K. Dhingra), 263-269;
1988, Metals Park, OR, ASM International.
16. c. M. ADAMS and R. E. LEWIS: in 'Rapidly solidified crystalline
alloys', (ed. S. K. Das et al.), 157-183; 1985, Warrendale, PA,
The Metallurgical Society of AIME.
17. M. S. ZEDALIS, J. M. PELTIER, and P. S. GILMAN: in 'Light-weight
alloys for aerospace applications', (ed. E. W. Lee et a!.),
323-334; 1989, Warrendale, PA, The Metallurgical Society
of AIME.
18. F. A. BADIA and P. K. ROHATGI: Trans. AFS, 1969, 76, 402-406.
19. A. M. PATTON: J. Inst. Met., 1972, 100, 197-201.
20. A. W. NEUMANN, C. J. van OSS, and J. SZEKELY: Kolloid-Z.u.Z.
Polym., 1973, 251, 415-423.
21. P. K. ROHATGI: in 'Interfaces in metal-matrix composites', (ed.
A. K. Dhingra and S. G. Fishman), 185-202; 1986, Warrendale, PA, The Metallurgical Society of AIME.
22. K. C. RUSSELL, J. A. CORNIE, and S.-Y. OH: in 'Interfaces in
metal-matrix composites', (ed. A. K. Dhingra and S. G.
Fishman), 61-91; 1986, Warrendale, PA, The Metallurgical
Society of AIME.
J. DINWOODIE, E. MOORE, C. A. J. LANGMAN,
International
Materials Reviews
1994
Vol. 39
No.1
22
23.
Lloyd
International
Materials Reviews
1994
Vol. 39
No.1
61.
.>
Lloyd
95.
P. B. PRANGNELL and w. M. STOBBS: in 'Metal matrix composites - processing; microstructure and properties', 12th Rise
Int. Symp. on Metallurgy and Materials Science, Rise
National Laboratory, Roskilde, Denmark, 1991, (N. Hansen
96.
97.
98.
I. DULTA, S. M. ALLEN,
et al.), 603-610.
106.
23
127.
International
Materials Reviews
1994
Vol. 39
No.1