Table of Contents

1. Introduction ……………………………………………………………………………… 3

2. Metal Matrix Composites (MMC) ………………………………………………………. 5

3. Aluminum Metal Matrix Composites …………………………………………………… 6

4. Types of Aluminum Metal Matrix Composites …………………………………………. 7

4.1. Particle reinforced aluminum matrix composites (PAMCs) ………………………... 7

4.2. Short fiber- and whisker-reinforced aluminum matrix composites (SFAMCs) ……. 8

4.3. Continuous fiber-reinforced aluminum matrix composites (CFAMCs) ……………. 8

4.4. Mono filament reinforced aluminum matrix composites (MFAMCs) ……………... 8

5. Al-MMC Application in Brake Rotors ………………………………………………….. 9

5.1. Properties of The Ultilite Composites ……………………………………………... 10

5.2. Testing of Ultilite Drums ………………………………………………………….. 11

6. References ……………………………………………………………………………… 12
 1. Introduction

Metal composite materials have found application in many areas of daily life for quite some
time. Often it is not realized that the application makes use of composite materials. These
materials are produced in situfrom the conventional production and processing of metals. Here,
the Dalmatian sword with its meander structure, which results from welding two types of steel by
repeated forging, can be mentioned. Materials like cast iron with graphite or steel with a high
carbide content, as well as tungsten carbides, consisting of carbides and metallic binders, also
belong to this group of composite materials. For many researchers the term metal matrix
composites is often equated with the term light metal matrix composites (MMCs). Substantial
progress in the development of light metal matrix composites has been achieved in recent
decades, so that they could be introduced into the most important applications. In traffic
engineering, especially in the automotive industry, MMCs have been used commercially in fiber
reinforced pistons and aluminum crank cases with strengthened cylinder surfaces as well as
particle-strengthened brake disks.

These innovative materials open up unlimited possibilities for modern material science and
development; the characteristics of MMCs can be designed into the material, custom-made,
dependent on the application. From this potential, metal matrix composites fulfill all the desired
conceptions of the designer. This material group becomes interesting for use as constructional
and functional materials, if the property profile of conventional materials either does not reach
the increased standards of specific demands, or is the solution of the problem. However, the
technology of MMCs is in competition with other modern material technologies, for example
powder metallurgy. The advantages of the composite materials are only realized when there is a
reasonable cost – performance relationship in the component production. The use of a composite
material is obligatory if a special property profile can only be achieved by application of these
materials.

The possibility of combining various material systems (metal – ceramic – nonmetal) gives the
opportunity for unlimited variation. The properties of these new materials are basically
determined by the properties of their single components.

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The reinforcement of metals can have many different objectives. The reinforcement of light
metals opens up the possibility of application of these materials in areas where weight reduction
has first priority. The precondition here is the improvement of the component properties. The
development objectives for light metal composite materials are:

• Increase in yield strength and tensile strength at room temperature and above while
maintaining the minimum ductility or rather toughness,
• Increase in creep resistance at higher temperatures compared to that of conventional
alloys,
• Increase in fatigue strength, especially at higher temperatures,
• Improvement of thermal shock resistance,
• Improvement of corrosion resistance,
• Increase in Young’s modulus,
• Reduction of thermal elongation.

To summarize, an improvement in the weight specific properties can result, offering the
possibilities of extending the application area, substitution of common materials and
optimization of component properties. With functional materials there is another objective, the
precondition of maintaining the appropriate function of the material. Objectives are for example:

• Increase in strength of conducting materials while maintaining the high conductivity,

• Improvement in low temperature creep resistance (reactionless materials),
• Improvement of burnout behavior (switching contact),
• Improvement of wear behavior (sliding contact),
• Increase in operating time of spot welding electrodes by reduction of burn outs,
• Production of layer composite materials for electronic components,
• Production of ductile composite superconductors,
• Production of magnetic materials with special properties.

For other applications different development objectives are given, which differ from those
mentioned before. For example, in medical technology, mechanical properties, like extreme
corrosion resistance and low degradation as well as biocompatibility are expected.

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 2. Metal Matrix Composites (MMC)

As the name implies, for metal-matrix composites (MMCs), the matrix is a ductile metal. These
materials may be utilized at higher service temperatures than their base metal counterparts;
furthermore, the reinforcement may improve specific stiffness, specific strength, abrasion
resistance, creep resistance, thermal conductivity, and dimensional stability. Some of the
advantages of these materials over the polymer-matrix composites include higher operating
temperatures, non-flammability, and greater resistance to degradation by organic fluids. Metal-
matrix composites are much more expensive than PMCs, and, therefore, their (MMC) use is
somewhat restricted.

The superalloys, as well as alloys of aluminum, magnesium, titanium, and copper, are employed
as matrix materials. The reinforcement may be in the form of particulates, both continuous and
discontinuous fibers, and whiskers; concentrations normally range between 10 and 60 vol%.
Continuous fiber materials include carbon, silicon carbide, boron, alumina, and the refractory
metals. On the other hand, discontinuous reinforcements consist primarily of silicon carbide
whiskers, chopped fibers of alumina and carbon, and particulates of silicon carbide and alumina.
In a sense, the cermets fall within this MMC scheme. In Table 15.6 are presented the properties
of several common metal-matrix, continuous and aligned fiber-reinforced composites.

Some matrix–reinforcement combinations are highly reactive at elevated temperatures.

Consequently, composite degradation may be caused by high-temperature processing, or by
subjecting the MMC to elevated temperatures during service.

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This problem is commonly resolved either by applying a protective surface coating to the
reinforcement or by modifying the matrix alloy composition.

Normally the processing of MMCs involves at least two steps: consolidation or synthesis (i.e.,
introduction of reinforcement into the matrix), followed by a shaping operation. A host of
consolidation techniques are available, some of which are relatively sophisticated; discontinuous
fiber MMCs are amenable to shaping by standard metal-forming operations (e.g., forging,
extrusion, rolling).

3. Aluminum Metal Matrix Composites

In AMCs one of the constituent is aluminum/aluminum alloy, which forms percolating network
and is termed as matrix phase. The other constituent is embedded in this aluminum/aluminum
alloy matrix and serves as reinforcement, which is usually non-metallic and commonly ceramic
such as SiC and Al2O3. Properties of AMCs can be tailored by varying the nature of constituents
and their volume fraction.

The advantages of the reinforced matrix can be quantified for better appreciation. For example,
elastic modulus of pure aluminum can be enhanced from 70GPa to 240GPa by reinforcing with
60 vol.% continuous aluminum fiber. On the other hand incorporation of 60 vol% alumina fiber
in pure aluminum leads to decrease in the coefficient of expansion from 24 ppm/C to 7 ppm/C.
Similarly it is possible to process Al-9% Si-20 vol% SiCp composites having wear resistance
equivalent or better than that of grey cast iron. All these examples illustrate that it is possible to
alter several technological properties of aluminum/aluminum alloy by more than two– three
orders of magnitude by incorporating appropriate reinforcement in suitable volume fraction.

AMC material systems offer superior combination of properties (profile of properties) in such a
manner that today no existing monolithic material can rival. Over the years, AMCs have been
tried and used in numerous structural, non-structural and functional applications in different
engineering sectors. Driving force for the utilization of AMCs in these sectors include
performance, economic and environmental benefits. The key benefits of AMCs in transportation
sector are lower fuel consumption, less noise and lower airborne emissions. With increasing
stringent environmental regulations and emphasis on improved fuel economy, use of AMCs in
transport sector will be inevitable and desirable in the coming years.

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AMCs are intended to substitute monolithic materials including aluminum alloys, ferrous alloys,
titanium alloys and polymer based composites in several applications. It is now recognized that
in order AMCs substitution for monolithic materials in engineering system to be wide spread,
there is a compelling need to redesign the whole system to gain additional weight and volume
savings. In fact according to the UK Advisory Council on Science and Technology, AMCs can
be viewed either as a replacement for existing materials, but with superior properties, or as a
means of enabling radical changes in system or product design. Moreover, by utilizing near-net
shape forming and selective-reinforcement techniques AMCs can offer economically viable
solutions for wide variety of commercial applications.

Recent success in commercial and military applications of AMCs is based partly on such
innovative changes made in the component design. Lack of knowledge and information about
utilization possibilities, service properties and material producers have hindered the wider usage
of AMCs. Recognizing these peripheral and extraneous difficulties, AMCs community in USA
and Europe are pursuing consortium and networking approaches to implement the applications of
AMCs in everyday societal use.

4. Types of AMCs

AMCs can be classified into four types depending on the type of reinforcement as detailed.

4.1.Particle reinforced aluminum matrix composites (PAMCs)

These composites generally contain equiaxed ceramic reinforcements with an aspect ratio less
than about 5. Ceramic reinforcements are generally oxides or carbides or borides (Al 2O3 or SiC
or TiB2) and present in volume fraction less than 30% when used for structural and wear
resistance applications. However, in electronic packaging applications reinforcement volume
fraction could be as high as 70%. In general, PAMCs are manufactured either by solid state (PM
processing) or liquid state (stir casting, infiltration andin-situ) processes. PAMCs are less
expensive compared to CFAMCs. Mechanical properties of PAMCs are inferior compared to
whisker/short fiber/continuous fiber reinforced AMCs but far superior compared to unreinforced
aluminum alloys. These composites are isotropic in nature and can be subjected to a variety of
secondary forming operations including extrusion, rolling and forging. Figure 1a shows the

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microstructure of cast aluminum matrix composite having high volume fraction (40 vol%) SiC
particle reinforcements.

4.2.Short fiber- and whisker-reinforced aluminum matrix composites (SFAMCs)

These contain reinforcements with an aspect ratio of greater than 5, but are not continuous. Short
alumina fiber reinforced aluminum matrix composites is one of the first and most popular AMCs
to be developed and used in pistons. These were produced by squeeze infiltration process. Figure
1b shows the microstructure of short fiber reinforced AMCs. Whisker reinforced composites are
produced by either by PM processing or by infiltration route. Mechanical properties of whisker
reinforced composites are superior compared to particle or short fiber reinforced composites.
However, in the recent years usage of whiskers as reinforcements in AMCs is fading due to
perceived health hazards and, hence of late commercial exploitation of whisker reinforced
composites has been very limited. Short fiber reinforced AMCs display characteristics in
between that of continuous fiber and particle reinforced AMCs.

4.3.Continuous fiber-reinforced aluminum matrix composites (CFAMCs)

Here, the reinforcements are in the form of continuous fibers (of alumina, SiC or carbon) with a
diameter less than 20m. The fibers can either be parallel or pre woven, braided prior to the
production of the composite. AMCs having fiber volume fraction upto 40% are produced by
squeeze infiltration technique. More recently 3M Tm corporation has developed 60 vol%
alumina fiber (continuous fiber) reinforced composite having a tensile strength and elastic
stiffness of 1500 MPa and 240 GPa respectively. These composites are produced by pressure
infiltration route. Figure 1c shows the microstructure of continuous fiber (alumina) reinforced
AMCs.

4.4.Mono filament reinforced aluminum matrix composites (MFAMCs)

Monofilaments are large diameter (100 to 150m) fibers, usually produced by chemical vapor
deposition (CVD) of either SiC or B into a core of carbon fiber or W wire. Bending flexibility of
monofilaments is low compared to multifilaments. Monofilament reinforced aluminum matrix
composites are produced by diffusion bonding techniques, and is limited to super plastic forming
aluminum alloy matrices.

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In CFAMCs and MFAMCs, the reinforcement is the principal load-bearing constituent, and role
of the aluminum matrix is to bond the reinforcement and transfer and distribute load. These
composites exhibit directionality. Low strength in the direction perpendicular to the fiber
orientation is characteristic of CFAMCs and MFAMCs. In particle and whisker reinforced
AMCs, the matrix is the major load-bearing constituent. The role of the reinforcement is to
strengthen and stiffen the composite by preventing matrix deformation by mechanical restraint.

5. Al-MMC Application in
Brake Rotors
ULTALITE® is a low cost aluminum
metal matrix composite (AL-MMC)
that uses ceramic particles extracted
from flyash as the reinforcement
particulate. Australian developed
ULTALITE composites use ceramic

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particles to increase the wear resistance, provide high thermal conductivity, and give good
machinability for metal components, which is very desirable for brake rotors.

ULTALITE composites typically contain between 15% and 30% spherical ceramic particles.
However, unlike other more expensive composites, ULTALITE uses inexpensive ceramic
particles derived from flyash, a by-product of the power generation industry. It consists of
inorganic, incombustible matter formed during the combustion of powdered coal in electric
power generating plants, and consists mainly of SiO2 and Al2O3, along with other extraneous
impurities.

The flyash material solidifies while suspended in the exhaust gasses, and forms as amorphous,
spherical particles between 0.5 μm and 100 μm in size. Both hollow (cenospheres) and solid
(precipitator) flyash particles are formed, but only the solid particles are used in the ULTALITE
AL-MMC brake applications.

5.1.Properties of The Ultilite Composites

Table 1 shows typical properties of squeeze cast ULTALITE composites, and compares them to
hand book data for permanent mould A356-T6 and die cast 380. The figures show that
ULTALITE composites have strengths similar to die cast 380, but significantly higher than the
A356. Elongation of the ULTALITE composites is slightly lower than the die cast alloy, due to
the ceramic reinforcement particles in the composite.

Table 1: Typical mechanical properties of ULTALITE composites, along with handbook data
for permanent mould cast A356 and die cast 380

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 5.2.Testing of Ultilite Drums

Recently dynamometer has been performed. Dynamometer testing of 8inch diameter ULTALITE
brake drums, manufactured by the squeeze casting process, was performed at Brake Testing
International (BTI), located in Hinckley, England. The test regime followed procedures laid out
in SAE specification J25222. Standard off the shelf brake linings (Don #8259 and Nisshimbo)
were used in all the tests.

A series of fade segment 6.9 tests for three lining

combinations (cast iron + Nisshimbo,
ULTALITE+ Nisshimbo and ULTALITE+ Don
#8259) were conducted 7. The plots in the top
graph, which show brake factor, temperature and
applied pressure variations across 15 stops for an
OE cast iron + Nisshimbo combination, were used
as benchmarks.

The data shows that the ULTALITE brake drum

has higher brake factors. The average brake factors
for all ULTALITE brake lining combinations was
about 1.6 or above. The average brake factor for
the cast iron drum was around 1.2. The temperature
graph illustrates maximum temperature in the
ULTALITE brake drums never exceeded 185oC
with either lining, compared to a maximum
temperature of over 300oC for the cast iron +
Nisshimbo combination. This is due to the
significantly higher thermal conductivity of
Aluminum compared to cast iron, providing
significantly better heat dissipation characteristics.

Dynamometer testing also revealed that overall

lining wear was actually a little lower for the
ULTALITE drums, even when compared to
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conventional cast iron drums. This testing with ULTALITE brake drums has shown that special
brake linings are not required. In the past, excessive lining wear has been a problem with other
composites brake drums, where lining wear has been so high as to require the use of special
linings.

The extremely low lining wear of ULTALITE drums is probably a consequence of the spherical
nature of the ceramic reinforcement particles used with ULTALITE composites. Other AL-
MMC materials generally use angular ceramic reinforcement particles that can tear up the
linings.

In addition, due to superior heat dissipation, the

operating temperature of the ULTALITE brake
drums was more than 100°C lower than that of
the cast iron drums, thereby reducing brake
fade 8. This data shows that the ULTALITE
brake drum lining wear characteristics are
equivalent to, or better than, those of a cast iron
brake drum.

6. REFERENCES

[1] William D. Callister Jr, “|Materials science and Engineering, an introduction”. 7th Ed, Wiley
and Sons Publishing.
[2] M. K. Surappa, “Aluminum metal matrix composites: challenges and opportunities,”
Sadhana, vol. 28, no. 1-2, pp. 319–334, 2003.
[3] Karl U. Kainer, “Metal Matrix Composites: Custom-Made Materials for Automotive and
Aerospace Engineering”, Wiley and Sons Publishing, 2003
[4] U.S. Department of Defense, “Composite Materials Handbook Vol. 4: Metal Matrix
Composites”
[5] Rupa Dasgupta, “Aluminum Alloy-Based Metal Matrix Composites: A Potential Material for
Wear Resistant Applications”, ISRN Metallurgy, Volume 2012, Article ID 594573.
[6] Graham Withers, and Dr. Ren Zheng, “ULTALITE®– A low cost, lightweight aluminum
metal matrix composite for braking applications”.

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