Metal Matrix

Composite
Processing
Solid State Fabrication of Metal
Matrix Composites
 Solid state fabrication of metal matrix composites is the process , in
which MMC are formed as a result of bonding of matrix metal and
dispersed phase due to mutual diffusion occurring between them in
solid state at elevated temperature and under pressure.
 Diffusion bonding
 Powder Processing or powder Metallurgy
 In-situ processing
Diffusion Bonding Route

 It is a common solid-state processing technique for joining similar or

dissimilar metals. Inter diffusion of atoms between clean metallic
surfaces, in contact at an elevated temperature, leads to bonding.
It is also used for fabrication of MMC as shown in figure

https://www.youtube.com/watch?v=IQYZHGSf_8E
https://www.youtube.com/watch?v=7o9CfeS8cxs
 The principal advantages of this technique are the ability to process
a wide variety of metal matrices and control of fiber orientation and
volume fraction
Powder Processing or Powder
Metallurgy
 These methods in conjunction with deformation processing are used
to fabricate particulate or short fiber reinforced composites as
shown in fig. 6.
 This typically involves cold pressing and sintering, or hot pressing to
fabricate primarily particle- or whisker-reinforced MMCs.
 The matrix and the reinforcement powders are blended to produce
a homogeneous distribution.
https://www.youtube.com/watch?v=MgukjCT9o80
 The blending stage is followed by cold pressing to produce what is
called a green body, which is about 80% dense and can be easily
handled.
 The cold pressed green body is canned in a sealed container and
degassed to remove any absorbed moisture from the particle
surfaces.
 The material is hot pressed, uniaxially or isostatically, to produce a
fully dense composite and extruded.
Deposition Techniques

 These processes for metal-matrix composite fabrication involve

coating individual fibers in a tow with the matrix material needed to
form the composite followed by diffusion bonding to form a
consolidated composite plate or structural shape.
 The main disadvantage of using deposition techniques is that they
are time consuming.
 Several deposition techniques are available: immersion plating,
electroplating, spray deposition, chemical vapor deposition (CVD),
and physical vapor deposition (PVD), spray forming.
1. Spray Forming

 a co-spray process, uses a spray gun to atomize a molten aluminum

alloy matrix, into which heated silicon carbide particles are injected
Other Deposition methods

 Dipping or immersion plating is similar to infiltration casting except

that fiber tows are continuously passed through baths of molten
metal, slurry, sol, or organometallic precursors.
 Electroplating It produces a coating from a 10 µm solution
containing the ion of the desired material in the presence of an
electric current. Fibres are wound on a mandrel, which serves as the
cathode, and placed into the plating bath with an anode of the
desired matrix material.
Spray Deposition

 Spray Deposition :This technique typically consists of winding fibers

onto a foilcoated drum and spraying molten metal onto them to
form a monotape. The source of molten metal may be powder or
wire feedstock which is melted in a flame, arc, or plasma torch.
 Spray deposition techniques fall into two distinct classes, depending on whether
the droplet stream is produced from a molten bath or by continuous feeding of
cold metal into a zone of rapid heat injection
 Droplet velocities typically average about 20–40 m s−1. A thin layer of liquid,
or semisolid, is often present on the top of the ingot as it forms. MMC material
produced in this way often exhibits inhomogeneous distributions of ceramic
particles..

https://www.youtube.com/watch?v=-mcWhRg5w2A
Chemical Vapour Deposition
(CVD)
 Chemical Vapour Deposition (CVD) It is a vaporized component
decomposes or reacts with another vaporized chemical on the
substrate to form a coating on that substrate. The processing is
generally carried out at elevated temperatures.
 .
Precursors/Diluents

Typical precursors for CVD processes include:

• Oxygen
• Halides: H2SiCl2, HSiCl3, TiCl4, WF6, etc.
• Hydrides: SiH4, GeH4, AlH3(NMe3)2, NH3, etc.
• Organometallics: AlMe3, Ti(CH2tBu)4, etc.
• Metal Alkoxides: TEOS, Tetrakis Dimethylamino Titanium (TDMAT),
Ti(OiPr)4, etc.
• Metal Dialkylamides: Ti(NMe2)4, etc.
• Metal Diketonates: Cu(acac)2
• Metal Carbonyls: Ni(CO)4
CVD Advantages and disadvantages
Types of CVD
Co Deposition Methods

 Co-deposition is a process, in which matrix metal is deposited

together with the dispersed phase by one of the deposition
techniques.
 The following co-deposition methods are used for manufacturing
Metal Matrix Composites:

• Electrolytic co-deposition
• Spray co-deposition
• Vapor co-deposition
Electrolytic co-deposition

 This method (Electrolytic co-deposition) involves Electroplating technique, in

which electrolyte solution of matrix metal ions contains suspended particles of
dispersed phase. When the matrix metal is deposited on a substrate, the
dispersed phase particles are entrapped by the coating, reinforcing the matrix
material.
 Examples of electrolytic co-deposition:
• Nickel matrix composite materials with various dispersed phases are fabricated
by electrolytic co-deposition from Nickel Sulfamate and Watts electrolytes:
• Ni-Al2O3 - oxidation resistant nickel matrix composite;
• Ni-SiC – wear resistant nickel matrix composite;
• Ni-PTFE, Ni-C, Ni-MoS2 – antifriction nickel matrix composites.
• Anti-friction coating of Engine bearings consisting of lead-tin-copper alloy and
reinforced by alumina (Al2O3) is fabricated by electrolytic co-deposition from
electrolyte solution of lead, tin and copper with alumina particles.
• Aluminum matrix material reinforced by silica (SiO2) is prepared from AlCl3-
dimethylsulfone electrolyte containing fine silica particles.
Spray co-deposition

 This method implements Thermal spraying technique for atomizing

molten matrix metal, droplets of which are delivered to a substrate
in a high velocity gas stream together with dispersed phase particles
supplied to the stream from a separate container.
 The method allows fabrication of near-net-shape forming of Metal
Matrix Composites.
 Examples of spray co-deposition:
 Aluminum matrix material reinforced by silicon carbide (SiC) is
produced by spray co-deposition followed by Rolling.
 High Velocity Oxyfuel Spraying (HVOS) method is used for
fabrication tungsten carbide-cobalt (WC-Co) composite material,
which is conventionally manufactured by more expensive technology
of sintering fabrication of Metal Matrix Composites.
Vapor co-deposition

 Vapor co-deposition is a group of various methods, utilizing

materials in vapor state: Physical Vapor Deposition
(PVD), Chemical Vapor Deposition (CVD), Direct Vapor Deposition
(DVD).
 In these methods coating of solid material is formed as a result
of vapor condensation or chemical reaction on a substrate
surface.
 Vapor co-deposition is used for coating fibers,
creating multilayer depositions, fabricating nanostructure
composite materials.
D. In-situ Fabrication of Metal Matrix
Composites
 In these techniques the reinforcement phase is formed in situ. The
composite material is produced in one step from an appropriate
starting alloy, thus avoiding the difficulties inherent in combining the
separate components
 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.
Different types of Metal Matrix Composites may be prepared by in situ
fabrication method:
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 phases of in situ fabricated Metal Matrix Composites may consist
of intermetallic compounds, carbides, borides, oxides, one
of eutectic ingredients.
Advantages and disadvantages in in-situ fabrication of MMC

Advantages of in situ Metal Matrix Composites:

• In situ synthesized particles 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;
Vacuum infiltration method for
MMC
E. Two-phase Processes

 Two-phase processes like ospary deposition, compocasting, etc.

involve the mixing of ceramic and matrix in a region of the phase
diagram where the matrix contains both solid and liquid phases.
MIM

 Metal Injection Molding (MIM) is a near net-shape manufacturing

technology that is capable of mass production of complex parts
cost-effectively
 https://www.youtube.com/watch?v=MmLYj3GZsx8
 https://www.youtube.com/watch?v=Iw7dJfieNcw

 https://www.youtube.com/watch?v=6tHBntFsEDA