International Nano Letters

https://doi.org/10.1007/s40089-021-00328-y

REVIEW

A brief review of carbon nanotube reinforced metal matrix composites

for aerospace and defense applications
Venkataramanan Srinivasan1 · Selvaraj Kunjiappan2 · Ponnusamy Palanisamy1

Received: 23 November 2020 / Accepted: 6 February 2021

© Islamic Azad University 2021

Abstract
The aerospace and defense industry’s intense desire is to revamp the performance characteristics of space shuttle vehicles,
military tanker vehicles by continuously driving the production of advanced materials with remarkable properties. Thus, the
need for high strength and lower weight metals are increasing rapidly in these industries. In this view, many research works
on composites have been proved, especially metal matrix composites (MMCs). Carbon nanotubes (CNTs) are rolled-up gra-
phene sheets with superior mechanical, thermal, and electrical properties attracted by many researchers in fabrication with
MMCs. Metal matrix composites are developed in making space shuttle components and jet engine parts due to their higher
specific strength and wear resistance. Numerous experimental investigations were performed on CNT reinforced MMCs in
the making of structural components in aerospace and military vehicles, but the challenge still exists in many factors such as
the production of complex structural components with optimistic performance, poor scattering of CNT in MMCs due to the
formation of agglomeration and to retain nanoscale properties in large fraction. The aim of this review is to discuss about the
development of MMCs in aerospace and military applications, the importance of CNTs in the field of the aviation industry,
challenges in aerospace and defense sectors, and highlighting the importance of various processing techniques adopted in
the development of CNT reinforced MMCs.

Keywords Aerospace and defense applications · Carbon nanotubes · Metal matrix composite · Mechanical properties

Abbreviations Ti Titanium
CNT Carbon nanotube Cu Copper
SWCNT Single-walled carbon nanotube CF Carbon fibre
DWCNT Double-walled carbon nanotube SiC Silicon carbide
MWCNT Multi-walled carbon nanotube Al2O3 Aluminum oxide
MMCs Metal matrix composites Gr Graphene
Al-MMCs Aluminium metal matrix composites B4C Boron carbide
Ti-MMCs Titanium metal matrix composites Si3N4 Silicon nitride
Mg-MMCs Magnesium metal matrix composites TiO2 Titanium dioxide
Cu-MMCs Copper metal matrix composites TiC Titanium carbide
ECAs Electrically conductive adhesives TiB2 Titanium diboride
PDMS Polydimethylsiloxane Ni Nickel
Al Aluminium B Boron
Mg Magnesium Be Beryllium

* Ponnusamy Palanisamy
sreepons@gmail.com Introduction
1
School of Mechanical Engineering, Vellore Institute After significant active research progress over the years,
of Technology, Vellore, Tamilnadu 632014, India metal-based composite has contributed to industrial
2
Department of Biotechnology, Kalasalingam Academy and engineering practice [1]. Metal Matrix Composites
of Research and Education, Krishnankoil, Tamilnadu 626128, (MMCs) have higher strength and rigidity, greater operating
India

13
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temperature, considerable wear resistance than unreinforced
metals and the ability to adapt these properties for differ-
ent applications [2]. Composite materials contain a matrix
known as reinforcements or fillers with one or more physi-
cally different dispersed phases [3]. The reinforcement filler
is dispersed to the matrix to achieve the fascinating char-
acteristics such as excellent toughness, rigidity, durability,
thermal conductivity and coefficient of thermal expansion
[4].
The characteristics of the MMCs are significantly deter-
mined by the quality of the reinforcement and the interac-
tion between the metal matrix and the reinforcement. Their
composition specifies the reinforcements, proportions, mate-
rial properties, particle size distribution, and spatial extent
within the matrix [5]. Metal matrix composites are exten-
sively adopted in space and advanced electronics because
of its excellent properties such as remarkable strength,
hardness, and high elastic modulus. In general, aluminum
(Al), magnesium (Mg), titanium (Ti), copper (Cu), and their
alloys are widely used in the production of MMCs [6]. The
techniques adopted for composites’ progress are powder
metallurgy, stir casting, spray atomization, squeeze casting,
plasma spraying, and co-deposition. Silicon carbide (SiC),
aluminum oxide (­ Al2O3), and graphite (Gr) have commonly
used particle reinforcements for MMCs. These composites
properties and characteristics are determined by the size
and shape of the reinforcement and the bonding nature [7].
However, aluminum alloys are extensively utilized in aero-
space and other manufacturing sectors on account of their
outstanding thermal properties and less weight. Since alu-
minum alloy has a low melting point and low density, dif-
ferent reinforcement particles are used, such as SiC, boron
carbide ­(B4C), ­Al2O3, Silicon nitride ­(Si3N4), titanium oxide
­(TiO2), titanium carbide (TiC), titanium diboride ­(TiB2),
and Gr to get optimum performance [8]. Aluminum-metal
matrix composites (Al-MMCs) are commonly employed in
the automobile sector, aviation, structural applications of
defense fields [9]. Rotating parts, such as jet-engine com-
ponent require materials that have high endurance strength
and good thermal properties at higher temperatures. Tita-
nium matrix composites (TMCs) are good enough to use
in such applications because they give excellent corrosion
resistance, high strength, and resistance against temperature
reaction [10]. Many researchers and engineers have elevated
vision on magnesium alloys and their composites due to its
excellent strength and low-density properties [11].
In 1991, Iijima found carbon nanotubes (CNTs), a
graphene rolled-up sheet with a chemical bonding of s­ p2
hybridization [12]. The inclusion of CNTs in matrix materi-
als has remarkable benefits such as high strength to weight
ratio. Metal matrix composites reinforced with CNTs such
as carbon nanotube reinforced aluminum composites (CNT-
Al), carbon nanotube reinforced magnesium composites
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International Nano Letters
(CNT-Mg), carbon nanotube reinforced titanium compos-
ites (CNT-Ti) are actively investigated over a decade as
constructing aerospace structures, automotive, and defense
industries [13, 14]. Therefore, CNT reinforced Al-MMCs
are looking forward to becoming a significant next genera-
tion of lightweight and higher strength structural materials.
In this view, ex-situ CNTs and in-situ γ-alumina (γ-Al2O3)
reinforcement will be promising techniques in the manufac-
turing of Al-MMCs [15]. Indeed, the standard design used
to disperse filler in matrix materials is based on mixing and
milling operations. Hence by implementing a high dynamic
mixing process such as ball milling, a uniform dispersion
can be obtained. Usually, the mechanical properties of CNTs
have an elastic modulus of approximately 1–2 TPa [16].
Owing to transformable and straightforward processes,
high energy ball milling (HEBM) has become an attractive
method for uniform CNTs dispersion and scalability with
adequate CNT distribution. The carbon nanotube reinforced
aluminum (CNT/Al) composites fabricated by the high
energy ball milling process showed that the diameter and
morphology are well defined in the reinforcing effect of the
composite materials [17].
The uniform dispersion of graphene nanoplatelets rein-
forced magnesium-metal matrix composites (Mg-MMCs)
are obtained through a novel technique adopted by incorpo-
rating liquid state ultrasonic processing and solid-state stir-
ring [18]. However, before sintering, the CNTs are scattered
with the matrix powders in ethanol for homogeneous disper-
sion in sonication techniques. The milling speed adopted to
disperse the CNTs efficiently showed an extreme strain hard-
ening of matrix powders, leading to complications in refin-
ing the structure by the traditional powder metallurgy route
[19]. In structural applications, the CNTs reinforced MMCs
coatings provide better surface properties such as hardness,
toughness, and wear resistance. Many process technologies
for composite coatings are adopted, and electro-deposition
has shown many benefits, such as low-cost spraying and
sputtering processes. Very few researches are focused on the
pulse current in the electrodeposition of nickel-multiwalled
carbon nanotube (Ni/MWCNT) composite coatings, while
several studies were performed on Ni/MWCNT direct cur-
rent electrodeposition [20]. During the manufacturing of
CNT reinforced MMCs, various defects are attributed to the
aspect ratio, and unsaturated carbon and oxygen atoms are
supplied at the outer layer of CNT since unstructured carbon
and residual oxygen are present on the CNT surface. Boron
and nitrogen doping effects can interchange the chemical
properties of CNTs [21].
Carbon nanotubes reinforced MMCs are extensively used
in various applications due to their extraordinary properties.
However, there are some challenges still remains unclear
during the manufacturing of CNTs reinforced MMCs,
such as non-uniform dispersion of CNT in the composite,
International Nano Letters

formation of agglomeration and amorphous carbon during
processing. In this review, the importance of various pro-
cessing techniques adopted in the development of CNTs
reinforced MMCs which was done by previous researchers
are discussed and highlighting the different types of tech-
niques that are well suited to overcome the challenges like
the formation of agglomeration and poor dispersion of car-
bon nanotubes in metal matrix composites. The significance
of CNT reinforced MMCs in aerospace and defense sectors
were reviewed and why carbon nanotubes are promising
material with other carbon materials are reported. Develop-
ment of MMCs in aerospace and defense organizations are
highlighted.
Carbon nanotubes and other carbon materials
Carbon nanotubes and graphene
The techniques adopted in the synthesis of carbon nanotubes
are arc discharge method, laser ablation method and chemi-
cal vapour deposition. A CNT’s chemical reaction is evalu-
ated by comparing to a graphene sheet, which is improved as
a consequence of the circumference of the carbon nanotube
surface [22]. The modulus of multi-walled carbon nanotubes
(MWCNTs) developed through arc discharge method was
found to be 0.8 TPa and while preparing MWCNTs through
chemical vapour deposition 0.03 TPa was observed [23].
The development of carbon nanotubes from graph-
ite has a hexagonal arrangement of carbon atoms. The
Young’s modulus and tensile strength of single-walled
carbon nanotubes (SWCNTs) are found to be 0.27–0.9 TPa
and 11–63 GPa respectively as reported by Yu et al. The
material produced through graphene has higher strength,
stiffness and thermal conductivity. Zandiatashbar et al.
reported that the graphene has a breaking strength of
100 GPa although armchair and zigzag type graphene has
80 GPa and 75 GPa respectively. Graphene’s thermal con-
ductivity has found between 2000 and 5000 W/mK [24].
Table 1 shows the different properties of carbon nanotubes
and graphene.
Fan et al. reported that carbon nanotubes and graphene
structure has good electrochemical characteristics, that
implies the hybrid structure is appropriate to utilize as an
electrode in super capacitors [25].
Porous carbon
Recently porous carbon materials gained a lot of interest
particularly in the discipline of material science due to their
remarkable properties such as better electrical conductivity
and chemical stability. Porous carbon is prepared through
activation methods, template methods, direct carbonized
method and element doping method were widely utilized
on storage of hydrogen, adsorptivity of gases [26]. An earlier
study has shown that the design and development of porous
patterns is an efficient method to enhance the specific sur-
face area to around ~ 3000 ­m2/g, especially for micro and
mesoporous structures. Furthermore, the dissemination of
porosity and size control act as a vital role in controlling
the electrochemical method. The precise role and techniques
of porous carbon in lithium-ion batteries (LIBs) remains
unknown, although it has a remarkable effect in LIBs [27].
Nevertheless, earlier findings have shown that specific
surface area (SSA) by itself is inadequate to assess the effi-
cacy of porous carbon materials; this is due to the interior
pores are unfeasible for chemical reactions. The unavail-
ability of incomplete micropores is the crucial barrier to
the growth of pure form porous materials especially for
various superior geared applications [28].

Table 1  Various properties of CNTs and graphene

Property Carbon nanotube Carbon Fiber Monolayer graphene Graphene oxide Reduced Reference
graphene
SWCNT DWCNT MWCNT oxide

Young’s Modulus 0.97 ± 0.16 0.73 ± 0.07 0.018–0.068 0.965 1.0 0.208 ± 0.023 0.25 [24]
(TPa)
Tensile strength (GPa) 13–52 31 ± 4 1.4–2.9 3.0 1.3 × 102 0.077 ± 19.9 90
Fracture toughness 2.7 – – – 4–5 – 2.8–3
(MPa)
Room temperature > 105 – 104–105 – ~ 20 × 104 2–200 17–2000
­(cm2/Vs)
Thermal conductivity 6000 – 2000 – 1500–5000 2000 30–250
(W/mK)
Electrical conductivity 250–400 – – – 104 10–1 666.7
(S/cm)
Surface area ­(m2/g) ~ 400–900 – ~ 200–400 0.029 – 0.7 560.6 ~ 2630 –

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Carbon fibre
Carbon fibers or fibers usually in the range of 5–10 µm in
diameter and substantially consists of mainly carbon atoms.
Due to the excellent mechanical and thermal properties,
carbon fibers (CF) have been found in various applications
such as aerospace, defense, sports and automobile indus-
tries [29]. Carbon fibers are extensively used were strength,
stiffness; weight and good fatigue resistance are considered
to meet the requirements. Carbon fibers strength is found
to be 100 GPa, although the tensile strength of graphite is
150 GPa. Hence, the carbon fibres are particularly focused
on the making of structural components in various sectors
[30].
The carbon fibre reinforced plastic (CFRP) characteristics
stands on the distribution of carbon fibre. CFRP are widely
used in various applications as a substitute for traditional
materials like steel and iron owing to remarkable properties
such as low coefficient of thermal expansion, better fatigue
resistance with enhanced tensile and compressive strength
[31].
Carbon nitride and graphene quantum dots
Due to its excellent opto-electronic characteristics, graphitic
carbon nitride (g-C3N4) is becoming a significant material
in various applications. The benefits of g-C3N4 incorporated
material properties have enhanced sensitivity, high specific
surface area and chemical stability. However, when bulk
g-C3N4 is transfigured into nanosheets, it can be converted
into various microstructures, like nanorods/nanotubes and
quantum dots. Owing to its unique characteristics, such as
chemical stability, high aspect ratio and biocompatibility
graphene quantum dots have received considerable atten-
tiveness in various research fields [32].
Nevertheless, graphene carbon nitrides (g-CNs) have
several complications to be sort out. The first and foremost
challenge is optical related problems. Due to the structural
stability of graphene carbon nitride, it is very complicated
to regulate the energy level of g-CNs. However, this can be
eliminated by incorporating g-CNs with up-conversion nano
particles [33].
Diamond
Among all solids, diamonds have the greatest atomic size,
composed of carbon atoms in a tetrahedral structure con-
stituting a compact system with powerful covalent bonds.
The structural defects in a diamond are due to the exist-
ence of impure atoms in the structure. Nitrogen is the main
cause for impurities in diamond and the categorization of
a diamond is based on the incorporation of nitrogen [34].
At normal pressure and temperature, graphite is invariable
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International Nano Letters
structure of carbon while diamond is in a metastable state.
A well-defined characteristic of nanodiamonds compared
with carbon nanotubes and graphene is that various group of
atoms adhere with molecules can take place on the surface
of nanodiamonds without any changes in its unique proper-
ties [35].
Although CNT reinforced MMCs are developed by dif-
ferent processing techniques to improve materials’ mechan-
ical properties and specific methods showed an excellent
interface bonding between the composites. The purpose of
this review is to discuss about the development of MMCs
in aerospace and military sectors, the importance of carbon
nanotube in the aviation sector, challenges in aerospace and
defense industries, and various methods adopted in the pro-
cessing of CNT reinforced MMCs, which has been done pre-
viously by many researchers and highlighting the importance
of suitable processing techniques. We limit the discussion
on the strengthening mechanism of the composites, buckling
analysis of carbon nanotubes and tribological characteristic
of CNT reinforced MMCs in this review.
Processing techniques
Several manufacturing methods are introduced to manufac-
ture MMCs, such as squeeze casting, stir casting, centrifugal
casting, laser melting, and plasma spraying; these techniques
are termed as liquid phase techniques. Besides, solid-state
methods for the fabrication of MMCs are implemented, such
as powder metallurgy, diffusion bonding, and friction stir
processing (FSP) in which matrix material will retain its
properties during processing. Friction stir processing was
developed to modify metallic plates’ fine surface structure
and sheets on friction stir welding principles. A microstruc-
tural observation indicates smaller grains and an inhomoge-
neous dispersion of the CNT [36].
Carbon nanotubes are generally supplied in agglomerated
form, and various processing techniques are adopted to dis-
articulate and amalgamate them with the metal matrix com-
posites. Different processes introduced in fabrication include
molecular level mixing, nanoscale dispersion, colloidal mix-
ing, friction stir processing, ball milling, magnetic stirring,
and particle composite system mixing. Generally, the most
common method used for dispersing CNTs in MMCs is ball
milling, molecular level mixing, and colloidal mixing [37].
The most common and widely used method for prepar-
ing carbon nanotube reinforced metal matrix composites
(CNT-MMCs) is powder metallurgy. The second foremost
techniques for deposition of thin coatings of CNT-MMCs
and deposition of metals onto CNTs are electrodeposition
and electroless deposition. Melting and solidification tech-
niques are well suited for low melting point metals such as
magnesium [38].
International Nano Letters
Although, powder metallurgy (PM) through high-
energy ball milling (HEBM) technique has become the
primary access to develop carbon nanotube reinforced alu-
minum composites, which sought active collision during
ball milling to disperse CNT. A more extended period of
the ball milling process is required to get uniform disper-
sion will also turn to damage the CNTs structure [39].
Figure 1 shows the various processing techniques of car-
bon nanotube reinforced metal matrix composite (CNT-
MMCs) A technique called “flake powder metallurgy”
(flake PM) has been implemented in recent years to obtain
a homogeneous distribution of CNTs in metal matrix com-
posites. Initially, circular metal particles are first refined
into two-dimensional nano/micro-flakes by ball milling to
make their configurations more consistent with the one-
dimensional structure of CNTs [40].
However, high efficient copper–graphite (Cu–Gr) com-
posites developed by electrochemical deposition have been
accepted widely due to its outstanding benefits. The process
is simple, easy to control, and looks forward to mass produc-
tions [41].
Spark plasma and microwave sintering techniques with
extraordinary benefits might have remarkable effects on
the material properties which were identified by previous
studies. In various aspects of aluminum matrix composites,
hybrid composites have recently been introduced using more
than two forms of reinforcement [42]. Cold spraying (CS)
is a new form of deposition technique that enables excellent
quality coatings to be rapidly produced from a wide range
of materials [43].
Fig. 1  CNT reinforced MMCs
processing techniques
To produce bulk CNT reinforced metal and ceramic com-
posites, plasma spraying can be used effectively [44]. Spark
plasma sintering is a novel technique with the benefits of
minimum time of sintering and has shown better density and
properties than hot pressing [45].
Metal matrix composites (MMCs)
development in aerospace and defense
sectors
The progress of metal matrix composites made the step into
aerospace, automobiles, defense, and other sectors because
of their higher specific strength and low coefficient of ther-
mal expansion. Owing to the severe vacuum environmen-
tal effects, traditional construction materials such as steel
cannot meet the required strength, durability, and safety
management when employed in the structural membrane in
advanced space technology [46]. The mechanical properties
of various alloys are shown in Table 2.
Recent developments in the silicon carbide-aluminum
(SiC/Al) composite have given rise to a new range of engi-
neering materials for a broad range of defense and aeronaut-
ics applications. Therefore, to evaluate their potential in an
extensive range of applications, extensive knowledge of SiC/
Al corrosion characteristics is essential. An excellent single
and two-layer coating system was successful for the com-
posite giving excellent corrosion resistance [51] (Figs. 2, 3).
Simultaneously, discontinuously reinforced MMCs like
silicon carbide composites of particulate reinforced SiC/Al
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 International Nano Letters

Table 2  Mechanical properties of various alloys

Alloy types Ultimate stress (MPa) Yield stress (MPa) Elongation (%) Elastic modu- Reference
lus (GPa)

2014-T6 Aluminium 455 410 – 72 Naser et al. [46]

2014-T6 Aluminium 483 414 13 – Kadaganchi et al. [47]
Aluminium Lithium 8090-T8771 441.28 344.75 0.5–2.0 80.67 Naser et al. [46]
Aluminium Lithium alloys 400 250 6.4 – Sauermann et al. [48]
Magnesium ZCM711 275 185 12 45 Naser et al. [46]
Titanium alloy Ti–6Al–4V 900–950 800–920 5–18 10–113 Naser et al. [46]
Titanium alloy Ti–6Al–4V 1080 600–745 10–12 – Petrousek et al. [49]
Beryllium alloys 290–324 207–241 2–3 – Naser et al. [46]
Copper–Beryllium alloy 600–1280 340–1170 6–15 – Lomakin et al. [50]

Fig. 2  MMCs development in

space shuttle vehicles. Source:
https​://matma​tch.com/blog/
metal​s-in-space​-how-super​alloy​
s-chang​ed-the-rocke​t-lands​cape/

and graphite-aluminum (Gr/Al) are effectively implemented
for aerospace and industrial applications. MMCs, such as
boron-aluminum (B/Al), Gr/Al, graphite-magnesium (Gr/
Mg), and graphite-copper (Gr/Cu) are utilized for manufac-
turing spacecraft parts such as tubes and panels fabricated
by the method of diffusion bonding. The development of
boron-aluminum (B/Al) tubular struts used as the frame and
rib truss members was the first significant accomplishment
of continuous fiber-reinforced MMCs and as landing gear
connection of shuttle orbiter [52].
Metal matrix composites consist of pure beryllium (Be),
and aluminum with 20–62 vol% Be and remaining aluminum
are used to develop aerospace components. The method
adopted to formulate the powders is executed by investment
casting and semi-solid forming. The materials have a density
of 25% less than that of aluminum and stiffness is four times
higher than titanium, magnesium, aluminum, and steel [53].
By using the liquid metallurgy method, aluminum alloy-
titanium carbide (Al7075/TiC) and Al7075/red mud com-
posite samples are produced separately. The findings showed
a better enhancement in the strength and wear resistance
of the samples when combined with base alloy. Hence the
aluminum alloy-titanium carbide (Al7075/TiC) composite is
well suitable for automobile and aerospace applications [54].
Particulate reinforced MMCs have the benefits of easy
to manufacture with cost-effective and more quality com-
ponents. Therefore, there is a need for an energetic method
to develop particulate reinforced MMCs for aerospace and
other applications were strength, stiffness and wear resist-
ance are highly considered. In this view, the techniques such
as solidification, blending, mechanical milling and gas atom-
ization are mainly adopted to fulfil the needs [55].
MMCs reinforced with A ­ l2O3, Gr, SiC particles were
produced using the electric resistance furnace by liquid

13
International Nano Letters
Fig. 3  Future armor vehicles in
MMCs. Source: https​://www.
artil​eri.org/2012/11/leopa​rd-
revol​ution​-tank-peran​g-kota-tni.
html
metallurgy techniques. Preheating is carried out to remove
the wetting effects. The graphite-reinforced composite
has been defined by a low coefficient of friction and lower
wear rate obtained by adding silicon carbide to the com-
posite matrix [56]. A high energy ball mill technique was
employed to obtain a homogeneous dispersion of nanosized
­Al2O3 in Al–Al2O3 nanocomposite. The strength, ductility,
and hardness were enhanced by a significant increase in the
weight percentage of reinforcement nanoparticles [57]. In
pure aluminum, the elastic modulus can be enhanced from
70 to 240 GPa by reinforcing continuous aluminum fiber
with 60 vol% [58].
Compared with steel and nickel base materials, TMCs
have a high specific strength, stiffness providing 50% weight
reduction in the higher temperature of jet engine propulsion
systems than superalloys. These composites have a con-
tinuous development in making aircraft engines, frames,
automotive and space shuttles components. The standard
reinforcement includes continuously reinforced and discon-
tinuously reinforced titanium matrix composites [59]. Sur-
face MMCs are a category of new age engineered materials
where the surface of the material is changed by dispersing
the secondary phase in the form of particles or fibers and
no differences in chemical composition. Magnesium and
its alloys are recently used to construct frame in aerospace
and defense sectors due to their remarkable strength and
low density. The friction stir processing technique is widely
preferred in magnesium and its alloys to fabricate surface
MMCs [60].
Aluminum alloys
The global requirements for material selection in aerospace
industries are good corrosion and wear resistance, higher
elastic modulus and better fatigue resistance. The important
parameters to be considered in the designing or manufactur-
ing process are characteristics of reinforcing material, vol-
ume fraction and homogeneous distribution in the matrix
[61]. Composites of aluminum fly ash matrix acquired
significant attention in aviation applications where unique
rigidity is essential. The matrix composite hardness, tensile
strength and yield strength were found to be significantly
enhanced when there is a rise in fly ash inclusion and simul-
taneously reduction in ductility was noticed by Bhandakkar
et al. [62]. Aluminum metal matrix composites are widely
preferred in any type of structural membrane in space
shuttle vehicles due to its less weight and hold up against
stresses that take place during the action of the vehicle in
space mission [63]. Koli et al. [64] reported that to achieve
a desired property of aluminium matrix composites, powder
metallurgy route with sintering process will be a promising
technique for producing quality components in aerospace
applications. The inadequacy of defects and cracks in the
matrix leads to adeptly load transfer from aluminium alloy
Al7075 matrix to TiC reinforcement which gives enhanced
flexural strength. The strength and wear resistance was sig-
nificantly improved when there is an increase in the con-
tent of reinforcement [65]. Yan et al. [66] reported that a
natural frequency is always required for aerospace electronic
13

components to withstand in different working condition such
as vibration to retain the mechanical properties of the com-
ponent. The silicon carbide-aluminium composites (SiC/Al)
have a higher natural frequency when compared with other
alloys that extend the lifetime of the component with opti-
mistic performance.
Aluminium alloy Al7075 exhibits a substantial improve-
ment in wear resistance when the composites are produced
from the alloy 7075 [67]. Aluminum-metal matrix compos-
ites provides excellent properties of materials for defense
and aerospace parts such as high strength and stiffness,
better thermal conductivity and enhanced fatigue resist-
ance. The door part in the fuel tank and fins of F-16 fighter
aircraft are built from aluminum metal matrix composites
(AMMCs). The rotor blade, lower and upper swash plates of
Eurocopter EC 120 and N4 helicopters are constructed with
aluminum-metal matrix composites [68]. Hemanth et al. [69]
reported that aluminum alloy (LM 13) showed a substantial
improvement over corrosion resistance when the reinforce-
ment content of zirconium oxide ­(ZrO2) was increased in
chilled nano metal matrix composites (CNMMCs). The find-
ing revealed that there are no defects or cavity observed in
the composite. Metal matrix composite of discontinuously
reinforced aluminum (DRA) has isotropic properties and
have precise stiffness values that are up to 100% greater than
that of aerospace metal alloys [70]. Various experimental
studies revealed that when aluminum alloy combined with
zinc and magnesium possess remarkable strength that leads
to the development of these alloys for manufacturing air-
craft components [71]. The mechanical properties of hybrid
aluminum metal matrix composites Al-6061 blended with
silicon carbide and aluminum oxide (SiC + ­Al2O3) was sig-
nificantly enhanced with lower porosity after the incorpora-
tion of cerium oxide (­ CeO2). The tensile strength was also
significantly enhanced from 30 to 123 MPa with the addition
of 2.5 wt% cerium oxide ­(CeO2) [72].
Magnesium alloys
The tubular part of FREJA satellite made from Mg is the first
implementation of Mg in space technology in the year 1992
[73]. The utilization of magnesium and its alloys is fasci-
nating material for armor vehicles to reduce the weight for
an effective drive and improved performance by withstand-
ing enormous load that acts during the military operation
[74]. Magnesium metal matrix composites are light struc-
tural material having low density and exceptional mechani-
cal properties found several applications in the aerospace
and defense sectors. Silicon carbide reinforced magnesium
matrix composites have elevated wear resistance and bet-
ter opposition to creep when compared to A ­ l2O3 reinforced
magnesium matrix composites. Dey et al. [75] reported that
carbon nanotube reinforced magnesium matrix composites
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International Nano Letters
exhibit enhanced bonding strength and wettability property
of the composite. The inclusion of graphene nanoplatelets
with increased content in magnesium matrix composite
shows significant progress in mechanical properties with
greater strength and optimistic performance as reported by
Xiang et al. [76]. Due to its lightweight in nature, magne-
sium and its alloy can be viewed as a suitable material to
build a aircraft structural frame were weight reduction is
considered as a main factor, since the specific gravity of
magnesium is 1.7 as compared with widely used aluminum
alloys (specific gravity is 2.7) in the aerospace sector. How-
ever, further attention is needed to increase the mechanical
properties of magnesium and its alloys for effective use in
aviation industries [77]. Microstructure refining, resulting
in superplasticity in some alloys, has been one of the ways
to enhance the high strength of magnesium–aluminum–zinc
(Mg–Al–Zn), magnesium–zinc–zirconium (Mg–Zn–Zr), and
magnesium–lithium (Mg–Li) alloys for producing complex
shape structures with improved mechanical properties for the
aerospace industry. Several aerospace components are fabri-
cated from magnesium alloy by casting and machining [78].
Magnesium alloys (QE22A, EV31A, ZE41A, and WE43B)
when combined with rare earth elements exhibit an ampli-
fied elevated temperature requirement, was proposed for the
aerospace parts working at a temperature of 250 °C [79].
Magnesium alloy are attractively laid out in making trans-
mission parts for aircraft models such as Eurocopter EC 120,
NH 90 and MD 500 and also enrolled in the application of
missile and spacecraft. The jet engine corporation has con-
tinued to use few volumes of magnesium alloy for making
quality components in both commercial and military appli-
cations [80]. Arruebarrena et al. [81] reported that magne-
sium alloy fabricated through investment-casting technique
have shown adequate characteristics and better mechani-
cal properties for their use in the aeronautical field. The
mechanical and tribological properties of magnesium alloy
are enhanced by adding reinforcement filler such as ­Al2O3,
SiC, and ­B4C [82]. The hardness value found increased
from 49 to 53 BHN of chromium coated magnesium alloy
AZ31 prepared by electroplating technique in particular for
aerospace application [83]. The reinforcement of fibres or
ceramics in magnesium alloy exhibit significant progress in
wear resistance [84]. Anbarasan et al. [85] reported that the
strength and hardness of the composite was considerably
improved when titanium diboride is blended with different
weight percentage (2 wt%, 4 wt%, 6 wt%) in magnesium
matrix composites through powder metallurgy technique.
Titanium alloys
The early design of titanium alloy in both purest form of
metals and even as alloys in the mid-1950s was prompted by
the aerospace and defense industries. The overall structural
International Nano Letters
components of aircraft SR-71 Blackbird was made from
titanium [86]. Titanium alloys seems to grow more popu-
lar with distinct physical features close to those of Carbon
Fiber Reinforced Plastic (CFRP) in the making of aircraft
structures. Since titanium alloy (Ti–6Al–4V) maintains
good characteristic at elevated temperatures with remark-
able strength they are used in making engine components of
the aircraft. The motive of using titanium alloys in aerospace
is due to its less weight, good corrosion resistance, and low
coefficient of thermal expansion [87]. For the production
of airframes, engine components, pipes, transmission gear
parts, exhaust system, and ducts, titanium alloys namely tita-
nium–aluminum–vanadium (Ti–6Al–4V), (Ti–3Al–2.5V),
titanium–vanadium–iron–aluminum (Ti–10V–2Fe–3Al),
tit anium–aluminum–tin–zirconium–molybdenum
(Ti–6Al–2Sn–4Zr–2Mo) and titanium–vanadium–chro-
mium–tin–aluminum (Ti–15V–3Cr–3Sn–3Al) are com-
monly used. Titanium alloy (Ti54M), nevertheless, is quiet
restricted to operate up to 315 °C range; even though the
alloy has good mechanical properties [88]. Considerable
specific strength of titanium alloy is not preferred for the
construction of aircraft components where rigidity plays
the major requirement. Alpha (α)—titanium alloys show
a greater opposition to creep and oxidation to bring about
appropriateness of working at higher temperature [89]. San-
thosh et al. [90] reported that Beta (β)—titanium alloys have
attracted greater attention by several researchers around the
world for effective utilization of these alloys in the construc-
tion of airframe structures. However, heat treatment is one
of the important processes to be considered in fabricating
these alloys. Even though titanium alloys hve extraordi-
nary mechanical properties, they have high limitations
in machinability due to its high chemical reaction during
operation. Titanium alloy Ti54M (α + β) alloy is designed
to increase manufacturing costs compared to Ti–6Al–4 V
alloy while offering similar characteristics to Ti–6Al–4 V
alloy but with improved machinability [91]. The method of
Digital Material Representation (DMR) was used to execute
the two-phase Ti–6Al–4 V alloy’s deformation characteris-
tics. A strain was noticed in (Ti–6Al–4 V) alloy not beyond
in alpha phase, although excessive stress was identified in
the beta phase [92]. A strong stability of properties such as
the ability of a material to withstand tensile or compressive
load, ductility, and creep resistance can be attained in exist-
ing γ-TiAl-based alloys [93]. The α phase titanium alloy
(Ti–5–2.5) which possess good ductility properties are often
utilized in space rocket engines which operates at − 250 °C.
Generally, gamma-Ti aluminides are used in making turbine
blades working at a temperature of around 700 °C [94]. Nev-
ertheless, advanced engineering and production techniques
are required to meet prospective need for the aerospace sec-
tor. Titanium alloy (Ti–6Al–4V) fabricated through addi-
tive manufacturing exhibit an improved surface finish. Hot
isostatic pressing (HIP) method accelerates to reduce the
porosity of the titanium alloy [95]. Peng et al. [96] reported
that (Ti–6Al–4V) titanium alloy with plasma electrolytic
oxidation (PEO) coating provides greater prospective
for aerospace components such as fasteners to overcome
normal deformation of the material. Friction stir welding
(FSW) technique for fabricating titanium alloy (6Al–4V) is
a feasible choice for producing custom blanks for effective
utilization in the production of industrial superplastic form-
ing (SPF) aerospace components [97]. Aluminum-titanium
alloys fabricated through powder metallurgy technique
exhibit improved hardness with less density, thus these
alloys are also a smart alternative to substitute heavy met-
als for less weight and aeronautics applications [98]. In
aircrafts structures, titanium remains viable and essential
at supersonic and hypersonic speeds (SR71) with access to
aluminium operating at a temperature of 250 °C [99].
Carbon nanotube (CNT)—emerging material
in military aircraft and space vehicles
One of the most distinctive inventions in the field of nano-
technology is the CNTs. CNTs are generally classified as
single-walled carbon nanotube (SWCNT), double-walled
carbon nanotube (DWCNT), and MWCNT. Lightweight,
enhanced tensile strength, high aspect ratio, and suitable
thermal property are the essential features of CNT, making
a special reinforcement in various composites like polymer,
metal matrix, and ceramic matrix composites [100] (Fig. 4).
Carbon nanotubes have attracted many scientific fields
due to their unique recognition, making it more attractive
to construct military aircraft, space vehicles, unscrewed
aerial vehicles, and satellite launch vehicles. Consequently,
attention is directed to further using CNT in lightning pro-
tection for aircraft, minimizing weight in space satellites
and frames. In military applications, the function of CNTs
comprises a coating, incorporated active material elements,
and structural material reinforcement [101].
A new chemical approach (covalent ester linkage) was
implemented to bond CNT on to CF by direct covalent
bonding to form a well-defined reinforcing structure. CNT
mechanical fracture was identified from the experiment, and
the occurrence of powerful carbon–carbon covalent bonding
is developed with high strength. This high strength bonding
can progress through advancement in composite structure
for next-generation advanced aerospace materials [102]
(Fig. 5).
Thermal regulation and electromagnetic energy-efficient
preservation of composite materials and energy storage asso-
ciated applications were incorporated in the advancement of
space application with graphene nanoplatelet membranes.
Multi-walled carbon nanotube showed a high thermal
13
 International Nano Letters

Fig. 4  CNTs for next generation

space vehicles. Source: https​://
www.natco​at.com/coati​ngs/

Fig. 5  Structure of Carbon

nanotubes. Source: https​://www.
nanow​erk.com/nanot​echno​logy/
intro​ducti​on/intro​ducti​on_to_
nanot​echno​logy_22.php

conductivity of 2500–3000 W/mK and for SWCNT is about
3500 W/mK that in turn, makes excellent protection for
structural membranes against environmental effects [103].
Disclosure to excessive energy molecule radiation in
human-crewed space mission has various health prob-
lems such as cardiac arrest, cataracts, and nerve system
malfunctioning. Proton radiation is an essential param-
eter for constructing safeguarding materials because it
covers an enlarged portion of space radiation particles.
Single-walled carbon nanotube (SWCNT) with doped
polydimethylsiloxane (PDMS) was built for proton shield-
ing tests. Investigation revealed that less loading (1.12 wt%)
of SWCNT enhances the proton shielding capacity in the
PDMS matrix [104]. The tensile property of AZ31 magne-
sium matrix composites will be improved by incorporating
1 wt% of MWCNT, and higher yield strength is obtained
when adding 15 vol% of CNT in the copper matrix [105].
Carbon nanotubes are preferred as filler for electrically
conductive adhesives (ECAs) in aerospace structural parts
with a large aspect ratio, high electrical conductivity, and

13
International Nano Letters
outstanding resistance to oxidation. Li et al. examined CNT-
filled adhesives as a substitute for tin/lead solder for aero-
space industries. High conductive ECAs based on silver-
coated CNTs were attained by Wu et al. [106]. There is a
need for continuous improvement in conductive adhesives to
construct an eminent frame in aircraft structural components
to overcome many issues. Therefore, CNTs provide a prom-
ising route for the growth of both structural and conductive
bonding of an aerospace adhesive [107]. Table 3 shows the
findings/observation of CNTs reinforced composites done
in previous articles.
Carbon nanotubes: a distinct material
application in various fields
Chaudhary et al. [114] reported that hybrid composites with
a nickel cobaltite (­ NiCo2O4) material on the surface of poly-
aniline (PANI) embodied CNTs with different geometries
have been developed and produced by combining in-situ
polymerization and co-precipitation methods. At a current
density of 1 A/g, phase change material PCM3 showed an
excellent specific capacitance of 2000 F/g with enhanced
rate capacity and structural steadiness. Hence, the distinct
characteristic of the composites is well suitable for the appli-
cation in energy storage devices (Table 4).
Sharma et al. [115] carried out a new investigation that is
the composites are developed from polymers incorporating
graphene hybrid carbon nanostructure, amine-functionalized
MWCNTs and poly (aniline-co-pyrrole). The 02-PANI-CO-
PPY-C composite had the maximum electric capacitance
of 337.35 F/g at a scan rate of 10 mV/s and 193.06 F/g at
50 mV/s. There was a greater thermal performance of the
composites than that of the copolymer. Hence this composite
is an optimistic material for the utilization in electrochemical
supercapacitors system.
Sharma et al. [116] reported that to increase the capaci-
tive characteristics of PANI and carbon nanotubes, the
materials were doped with varied proportions of copper
and nickel metal ions through in-situ chemical polymeriza-
tion. X-Ray Diffraction (XRD) analysis showed an improved
proper ordering of polymer chain in the composites and field
emission scanning electron microscopy (FESEM) findings
revealed that a homogenous coating of PANI over carbon
nanotubes was observed. Table 5 shows the specific capaci-
tance of the samples at various scan rates. For the prepared
samples with the highest doping rate, the maximum capaci-
tance value of 1337 F/g was achieved.
Bhardwaj et al. [117] prepared a composite with fine
PANI layers enclosed on the exterior of a hybrid carbon
(HC) through the oxidative polymerization method. Amine
functionalized multi-walled carbon nanotubes (AMWCNT)
and graphene (0.1 g) had undergone ultrasonication for 2 h
to develop the fine hybrid carbon array. The developed com-
posites were named as 025PANI-HC, 05PANI-HC, 1PANI-
HC and 2PANI-HC. The prepared sample of 025PANI-HC
showed a higher specific capacitance of 1397.82 F/g at a
scan rate of 5 mV/s and 1430 F/g for charge–discharge data
in 1 M H­ 2SO4. Hence it is a favourable material for electro-
chemical energy storage applications (Table 6).
Bhardwaj et al. [118] reported that through in-situ polym-
erization reaction of thiophene (Th) molecules on carbon
fibre (CF) and with graphene as reinforcement material, the
polythiophene (PTh) affixed three-dimensional carbon fibre
composite were prepared. The amalgamation of graphene
in the composite material exhibit a fine crystal structure
as indicated through XRD and SEM analysis. The electro-
magnetic interference shielding efficacy of the composite is
observed from − 15 to − 30 dB.
Kharangarh et al. [119] reported that by co-doping of sul-
phur and iron atoms with graphene quantum dots, an effec-
tive electrode material (Fe(II)S-GQDs) were developed. A
hydrothermal technique was adopted to evolve a high stable
material by choosing ferrous sulphate powder ­(FeSO4·7H2O)
and graphene oxide (GO) as a forerunner material. The
specific capacitance of Fe(II)S-GQDs was accomplished
to 476.2 F/g with outstanding characteristics in contrast to
graphene quantum dots (GQDs) of 143 F/g.
Paul et al. [120] prepared a cuprous oxide enclosed with
graphitic carbon nitride through hydrothermal technique and
the structural characteristics were analysed through SEM
and XRD. The surface area of the nanocomposite was sig-
nificantly increased and amplifying electrocatalytic perfor-
mance (148.7 mV with a current density of 12.8 mA/cm2
and Tafel slope 55 mV/dec). Hence, the nanocomposites
act as an appropriate catalyst to produce a clear source of
hydrogen.
Singh et al. [121] reported that MWCNTs were devel-
oped on the carbon fibre (CF) surface through chemical
vapour deposition technique and used as reinforcement in
epoxy resin to evolve as multi-scale CF felt MWCNT/epoxy
composites. The flexural strength (FS) and flexural modu-
lus (FM) was escalated when there is an increase in quan-
tity of CNT in carbon fibre surface. The flexural strength
was enhanced by 37%, which is 119 MPa in comparison
to 87 MPa for CF/epoxy composites and flexural modulus
also enhanced by 153%, which is 15.7 GPa in comparison
to 6.2 GPa for CF/epoxy composites.
Challenges in the aerospace and defense
industry
Since there is a vast development in aerospace materials
production, significant challenges arise, such as inadequate
mechanical properties that are limited to growing demand
13
13
Table 3  Findings/observation of CNTs reinforced composites
Title
CNTs: MMC
CNT composites for aerospace applications
State of the art review on carbon nanotubes
reinforced metal matrix composites
Advanced composite materials of the future in
aerospace engineering
An overview of the recent developments in
metal matrix nanocomposites reinforced by
graphene
Advanced composite material for aerospace
application—a review
Aim/objective
Recent development of CNT–MMCs
Epoxy resin was blended with graphite and
CNT with varied proportions to study electri-
cal properties
Mechanical, thermal, electrical properties of
CNT reinforced MMCs are discussed
To discuss about the roles and development of
composite materials in airframe structural
applications
To highlight the recent progress in powder-
based manufacturing, characterization of
aluminum, magnesium, titanium, copper
and nickel. Novel nanocomposites are also
discussed
To review about the composite materials and
advanced composites used as structural
applications in aircraft
Type of research Findings Reference
Review Homogeneous distributions of CNT in MMCs Carreno-Morelli et al. [108]
are the challenges to be resolved. Suitable
processing techniques should be adopted to
produce bulk MMCs
Research There is a difference in resistivity when the Belluci et al. [109]
percentage of CNT varies. So it is essential
to study the inclusion of CNT with different
proportions in the composite
Review CNT reinforced MMCs are found in limited Silvestre [110]
applications due to various challenges arises
in fabrication
Review A new technology should be implemented to Kamali et al. [111]
develop a composite material since the initial
cost for the fabrication of composite is high
Review Previous studies mainly focused on produc- Dadkhah et al. [112]
tion. Homogeneous distribution of nanopar-
ticles in the composite is a challenging one.
Special attention should be given in process-
ing techniques. Very few studies reported on
tribology of MMCs-Gr
Review Production of CNT with a large scale is a chal- Arif et al. [113]
lenging one. More attention should be given
to the repair mechanism. Manufacturing cost
of the composite to be considered
International Nano Letters
International Nano Letters

Table 4  Different composition Sample Aniline (M) CNTs (g) Co(No3)2·(6H2O) (g) Ni(No3)2·(6H2O) (g) Reference
of the samples
PANI 0.1 – – – Chaud-
PCM1 0.1 0.04 g 0.5 g 1g hary
et al.
PCM2 0.1 0.04 g 1g 2g
[114]
PCM3 0.1 0.04 g 2g 4g
PCM4 0.1 0.04 g 3g 6g

Table 5  Specific capacitance of Scan rate Specific capacitance (F/g) Reference

samples at various scan rates (mV/s)
PANI PANI-C MCP1 MCP2 MCP3 MCP4

5 445 656 889 968 1096 1337 Sharma

10 410 622 853 933 1055 1298 et al.
[116]
25 371 580 813 894 1014 1261
50 311 522 748 834 954 1189
100 259 471 678 746 832 1014

Table 6  Specific capacitance of Current den- HC (F/g) PANI (F/g) 2PANI- 1PANI- 05PANI- 025PANI- Reference
hybrid carbon (HC), polyaniline sity (A/g) HC (F/g) HC (F/g) HC (F/g) HC (F/g)
(PANI) and PANI-HC
composites 1 217 387 716 930 1273 1430 Bhardwaj
1.5 135 221 461 594 900 983 et al.
[117]
2 85 137 377 505 582 777

[105]. Although MMCs are typically more rigid and more
robust than unreinforced metal, they are vulnerable to
lower ductility. Hence ductility is to be considered along
with strength in making aerospace structural components.
The minimum ductility required for most space applica-
tions is 3–5%. However, the main challenge associated
with the designing of MMCs material is culture. Machin-
ing, joining, reinforcement, bonding are the other chal-
lenges faced during the manufacturing of MMCs [122].
The primary issue faced by the aerospace sector with
advanced composites is structural repair. Composite mate-
rials are usually impaired due to mechanical loading and
other outside factors. Bonding composite repair is gener-
ally transmit enough stress and enhanced joint efficien-
cies. However, many challenges still exist with present
technology [123].
The inclusion of materials in space vehicle engines oper-
ating at higher temperature needs microstructural stability,
high strength, high temperature creep resistance, fatigue
resistance, and other environmental factors. Increase engine
efficiency through materials operating at higher tempera-
tures. Various factors are considered, such as development
and control of microstructure, novel test techniques to deter-
mine the deformation rate of materials, and crack forma-
tion in engines. The engines are subjected to various load
conditions and other environmental factors in which the cor-
rosion and oxidation effects are mainly considered [124].
Composite materials in aerospace are multiplying and
creating many surface treatment challenges, coatings for
aerospace bodies and structures. The space shuttles experi-
ence various loads and environmental effects such as cor-
rosion, oxidation resistance, and wear resistance due to
the altitude changes. Therefore, a proper metal coating is
required to increase the performance of shuttle vehicles in
different stages. Thermal coatings in aircraft vehicles face
adhesion and conductivity problems. Many studies are done
in composites for coatings such as aluminum, magnesium,
titanium, nickel, zinc, and alloys, and still, there is a big
challenge in corrosion and wear resistance [125].
The primary reason for structural failure in military and
commercial aircraft is fatigue cracking. Hence care should
be taken in the selection of materials and design to minimize
the cracking effect. Surface finish, environmental factors,
material microstructure is the other factors associated with
cracking. Therefore, the primary failure occurs in aircraft,
causing a sudden effect in which it is difficult to overcome
due to various aspects [126].
Hence there is a need for proper method and technology
to manufacture the components with advanced composites
is essential. The missiles and aircrafts used in defense are

13

mainly depending on the material characteristics and sur-
face treatments. The biggest challenge in armor vehicles
is weight reduction. Today many advanced materials and
technology are stepped into defense applications, but there
is demand still exists.
Previous research work done in fabrication
on CNT reinforced MMCs by various
techniques
Liu et al. [127] executed a new method, namely solution-
assisted wet mixing technique is adopted for the significant
development of carbon nanotube reinforced aluminum
(CNT/Al) composite powders. The CNT/Al powders of dif-
ferent content 7.5 vol% 1.5 vol% and 3 vol% were developed
by a powder metallurgy method, resulting in substantially
improved tensile strength due to uniform CNTs distribu-
tion and low structural damage. The experimental intensity
of strength is increased by measuring the shear lag model,
which shows the high efficiency of load transfer from the Al
matrix to CNTs.
Zare et al. [128] reported that the aluminum matrix com-
posites reinforced with CNTs are synthesized using the Bc
equal-channel angular extrusion (ECAP) route and their
mechanical behaviour is investigated under compression and
shear deformation. The reinforced composites with 2 vol%
of CNTs show an improvement in yield strength and a higher
density of about 30% relative to the pure aluminum sam-
ples. The study revealed that 8 ECAP passes are required
to obtain improved mechanical properties with the CNT.
Table 7 shows the mechanical properties of aluminum and
CNT reinforced aluminum composites. The fractographic
study showed that composite fracture surfaces display more
brittle characteristics than pure Al.
Rikhtegar et al. [129] used the semi-wet (SW) and slurry-
based (SB) methods to synthesize aluminum with 1.5 wt%
CNT nanocomposites powder. The yield strength and tensile
strength of pure aluminium showed 90 MPa and 136 MPa
and substantially increased to 110 MPa and 170 MPa for
semi-wet (SW) specimen and enhanced to 152 MPa and
203 MPa for slurry-based (SB) specimen by the inclusion
of 1.5 wt% CNT to pure aluminium.
Habibi et al. [130] reported that nano-composites mag-
nesium/aluminum-carbon nanotube (Mg/Al–CNT) was
Table 7  Properties of aluminium and CNT reinforced aluminium composites
ECAP passes Shear strength (MPa) Yield strength (MPa)
2, 4, 8 passes Aluminum Aluminum-CNT com- Aluminum Aluminum-CNT com-
posites posites
79–117 92–132 57–81 85–94
13
International Nano Letters
fabricated using a powder metallurgy route that involved
microwave-assisted rapid sintering and hot extrusion. Due to
Al–CNT particles of varying length scale and CNT content,
a substantial reduction in Mg grain size is noticed. Com-
pared to the monolithic Mg, Al–CNT particles’ inclusion
decreases basal texture strength and emphasizes the pris-
matic surface. The mechanical strength has significantly
increased between Mg and CNT when Al is used as a bind-
ing agent.
Yang et al. [131] investigated the nickel (Ni) catalyst
accumulation on Al powder’s surface by soak route with a
low Ni content 0.5 wt% and in situ synthesis of CNTs in Al
powder by chemical vapour deposition. The yield stress and
elastic modulus of 1.5 wt% CNT/Al composites prepared
by hot extrusion are 2.2 and 3.0 times as large as that of
the pure Al matrix, suggesting the viability of using this
synthesis route to produce the high mechanical properties
of the CNT/Al composites.
Liang et al. [132] executed a new technique was devel-
oped to prepare CNTs reinforced Mg nanocomposites
incorporating friction stir processing (FSP) and ultrasonic-
assisted extrusion method. Uniform dispersion of CNTs
could be observed in the magnesium AZ91D alloy. Mag-
nesium nanocomposites strength is enhanced significantly.
The mechanical properties of magnesium alloy with differ-
ent compositions of CNT are shown in Table 8. The ultimate
tensile strength of 1.0 vol % of CNTs/Mg nanocomposites
increased by 25.5% compared to the AZ91D alloy, and the
yield strength increased by 13.5%.
Jargalsaikhan et al. [135] investigated the three separate
sample composites of aluminum-carbon nanotubes (Al-
CNTs), including unmilled aluminum, unmilled aluminum
with carbon nanotubes and milled aluminum with carbon
nanotubes nanocomposites and samples were prepared
using a conventional ball mill technique. Scanning Electron
Microscope (SEM) readings show that Al powder particles’
morphology enhanced with higher rotation speed and mill-
ing time. Carbon nanotubes are dispersed uniformly over
the surface of Al powder as well as it is effectively distrib-
uted on the surface of milled Al with CNTs when compared
with unmilled Al with CNTs. The hardness of the milled Al
with CNTs increased at a rotational speed of 100 rpm and
200 rpm when compared with unmilled Al with CNTs.
Riaz et al. [136] reported that friction stir is a new tech-
nique that is beneficial for the fabrication of composites
Compressive strength (MPa) Reference
Aluminum Aluminum-CNT com- Zare et al. [128]
posites
42–97 47–156
International Nano Letters

Table 8  CNT/Mg composites Alloy type Tensile 0.2% Yield Modulus of Failure strain (%) Reference
and Magnesium alloy strength strength elasticity
mechanical properties (MPa) (MPa) (GPa)

AZ91D 310 ± 6 245 ± 6 41 ± 4 13.5 Liang, et al. [132]

315 ± 5 232 ± 6 40 ± 2 – Shimizu et al. [133]
AZ91D/0.5% CNT 357 ± 9 266 ± 4 43 ± 3 13.1
383 ± 7 281 ± 6 43 ± 3 –
AZ91D/1.0% CNT 389 ± 8 278 ± 8 46 ± 2 12.8
388 ± 11 295 ± 5 49 ± 3 –
AZ91D/1.5% CNT 340 263 48 9.4 Liang et al. [132]
AZ91D/2.0% CNT 327 ± 8 254 ± 5 48 ± 4 5.3 Liang et al. [132]
263 ± 5.5 197 ± 4.5 – 8.7 ± 0.2 Sharif et al. [134]

reinforced with particles of a sub-micron size especially in
lightweight metal matrix composites and investigates the
ability of aluminum alloy AA6061 based surface nano-com-
posites by strengthening it with reinforcing CNTs. With the
addition of CNTs, a cumulative increase in micro-hardness
of 47.3% was observed and the maximum yield strength
53.2% was obtained from the base material.
Zheng et al. [137] used the electrochemical deposition
technique to prepare copper (Cu) with CNTs powders by
which CNTs could be thoroughly dispersed in the copper
electrolyte aided by sonication. Micro-hardness results
showed that Cu/CNT composites inflation of 20% was
observed with the addition of 0.42 wt% CNTs over pure cop-
per made using the same method. Electrochemical co-dep-
osition route shows the consistent distribution of CNTs and
strong interfacial bonding between CNTs and Cu because of
the electrostatic force applied during the process.
Kim et al. [138] reported that the friction stir welding
(FSW) technique has been widely used recently in the pro-
duction of MMCs, as the method overcomes specific issues
caused by other MMCs manufacturing processes. The FSW
technique and silver (Ag) embellished carbon nanotubes
(Ag–CNTs) were used to improve the thermal properties
of copper. Microstructural analysis showed that the disper-
sion of Ag-CNTs in Cu was significantly increased with a
number of passes (4 passes) in the composites. However,
the thermal properties found decreased when the number of
passes increased more than two.
Zheng et al. [139] investigated the titanium matrix rein-
forced with 1 vol% CNTs and 2.6 vol% TiC and produced
through mechanical blending accompanied by induction
heating, hot extrusion of the powder blend compacts. With
the rise in holding and extrusion temperatures from 1000 to
1200 °C, the volume fraction of the ultrafine-grained (UFG)
α-Ti regions reduced and the size of TiC particles rises from
1.2 to 4.6 mm, resulting increment in elongation to frac-
ture from 1.6 to 3.3% without a substantial transformation
in strength.
Esawi et al. [140] proved that ball milling is a promis-
ing technique in uniform dispersion of CNTs in the alu-
minum matrix. An improvement in tensile strength of 21%
was recorded for CNT (2 wt%) reinforced aluminum matrix
manufactured by cold compaction and hot extrusion. X-Ray
Diffraction and Transmission Electron Microscopy (TEM)
analysis reveals a little increase in crystal size after extrusion
at 500 °C and annealing at 500 °C for 10 h.
Kim et al. [141] reported that owing to the formation of
agglomeration in carbon nanotubes, hybrid reinforcement
found a suitable alternative technique to disperse CNTs
in composites uniformly. Multi-walled carbon nanotubes
(MWCNTs)/Al2O3sf preform based aluminum hybrid com-
posites were analyzed. Compressive strengths of hybrid
MMCs improved when compared with A356 aluminum
alloy by increasing the A ­ l2O3 fraction. The material was
adversely affected by the excessive content of ­Al2O3 or
CNTs due to the formation of agglomeration and poor wet-
tability with the matrix.
Xiong et al. [142] used spray pyrolysis (SP), low energy
ball friction and hot pressing methods to fabricate carbon
nanotube/copper-titanium (CNTs/Cu–Ti) composites. SP
and ball milling process increase the dispersion rate and
wettability of carbon nanotubes within the matrix. Simulta-
neously better adhesion of matrix with carbon nanotubes is
achieved and enhanced mechanical properties by the inclu-
sion of CNTs (0.4 wt%) in the composites. An enhanced
ultimate tensile strength (UTS) 352 MPa is obtained in
CNT/Cu–Ti alloy, which is 39% higher than copper-titanium
(Cu–Ti) alloy and 62% increased ductility when correlating
with alloy matrix. The mechanical properties of composites
are shown in Table 9.
Chen et al. [143] investigated the aluminium powder
and CNTs with different compositions and mixed for 2 h
using rock milling machines, and high energy ball milling
(HEBM). Aluminum matrix composites reinforced with
CNTs and in-situ nanoparticles γ-Al 2O3 have been for-
mulated to achieve consistently high tensile yield strength

13
 International Nano Letters

Table 9  Mechanical properties Composite with differ- Yield Tensile %Elongation Hardness (Hv) Reference
of composites with different ent CNTs composition strength strength
composition of CNTs (MPa) (MPa)

Cu–Ti/CNTs (0.0) 145 253 17.4 86.67 Xiong et al. [142]

Cu–Ti/CNTs (0.2) 173 295 25.8 94.52
Cu–Ti/CNTs (0.4) 192 352 28.2 100.86
Cu–Ti/CNTs (0.6) 175 302 24.3 97.74
Cu–Ti/CNTs (0.8) 152 266 15.1 88.22

(515 MPa), high tensile strength (542 MPa), high elastic
module (95.6 GPa) and excellent elongation (10.4 ± 0.8%)
with a density (2.735 g ­cm−3) which is identical to pure Al.
Xie et al. [43] reported that a complete dense carbon
nanotubes reinforced aluminum–silicon (CNT/AlSi) matrix
composite has been developed and successfully imple-
mented by the flake powder metallurgy method followed
by cold spraying (CS). In nanoscale formation, tiny grains
were accurately formed in the CNT/AlSi powder by shift
ball milling. Due to the CS cold aspect, it was observed that
no damage to CNTs structure and no combined reaction at
CNT/Al interface. Hence, CS will be a promising route for
processing and manufacturing complicated shapes in vari-
ous applications.
Liu et al. [144] reported that carbon nanotubes reinforced
aluminum matrix composite was prepared by including the
nano dimension and micron dimension Ti powders in Al-
CNTs composite. After the two-step ball milling (TSBM)
process, a relatively homogeneous CNT distribution was
achieved, enabled by the addition of Ti powders into the
composite powders.
Park et al. [145] implemented the squeeze infiltrated
method to fabricate the magnesium AZ91 alloy compos-
ites reinforced with CNTs. The Si coated MWCNTs has
enhanced interfacial strength in the composites. The tensile
strength also significantly improved. The tensile strength and
hardness value of the composite is shown in Table 10. Trans-
mission Electron Microscopy analysis shows that a good
adhesion and wettability between MWCNTs and matrix.
Fukuda et al. [146] reported that the elongation was
enhanced by removing the excess amount of magnesium
oxide (MgO) formation and decreasing the Mg matrix’s
induced strain. Carbide strengthened the interfacial bonding
between the Mg matrix and the CNTs, thereby enhancing the
mechanical properties of the AZ61/CNT composite when
compared to the magnesium alloy AZ61 composite without
CNTs.
Guo et al. [147] investigated the aluminum-magnesium-
silicon (Al–Mg–Si) composites reinforced with CNTs and
developed using powder metallurgy techniques. The disper-
sion, interfacial bonding, and densification of composites
produced by Al–Mg–Si/CNTs highly depend on the content
of CNTs. Owing to the varying dispersion of CNTs and oxy-
gen content, the precipitated particle properties were also
affected by the CNTs. However, the composite reinforced by
0.5 vol% CNTs showed good strength and ductility.
Yang et al. [148] reported that aluminum matrix com-
posites reinforced with CNTs were developed through a
modified powder metallurgy method, including in-situ syn-
thesis of CNTs on Al powders by chemical vapor deposi-
tion (CVD) and ball-milling method. Well scattered CNTs
without structural damage are deeply incorporated into Al
powder leading to a robust matrix bonding interface. The
hardness and tensile strength of CNT/Al composites were
found higher when increasing the amount of CNTs content.
When compared to Al at 100 °C, the coefficient of thermal
expansion (CTE) of 4.5 wt% CNT/Al composites found
decreases by 17%.
Mani et al. [149] found that ultrasonication of the CNT
and powder mixture in dimethylformamide (DMF) before
ball milling was more effective in uniform dispersion of
carbon nanotubes in the composites than in the ball milling
alone. The mechanical properties are significantly enhanced
by adding 1.5 vol% CNTs in the composites. Spark plasma
sintering is a significant manufacturing method for produc-
ing dense CNT composites with limited structural damage.

Table 10  Properties of MWCNT reinforced AZ91 magnesium composite

Alloy type Ultimate tensile Proof stress (MPa) Elongation (%) Hardness value Reference
strength (MPa) (Hv)

AZ91 magnesium alloy 205 ± 5 80 ± 5 5±2 80 Park et al. [145]

5 vol% pristine MWCNT/AZ91 243 ± 10 210 ± 10 1±2 150
5 vol% Si coating MWCNT/AZ91 296 ± 10 253 ± 10 1.3 ± 2 160

13
International Nano Letters
Dhore et al. [150] implemented a blind mold sintering
method to add more strength in the carbon nanotubes rein-
forced aluminum matrix nanocomposites. The addition of
CNT and tin (Sn) powder in aluminum has improved the
composites hardness and wear properties. After the sintering
process, the carbon nanotubes tend to retain their shape by
observation. The maximum hardness obtained is 73 BHN for
2 wt% Sn and 1 wt% CNT. There is a strong binding among
Al-CNT composites, which is observed through scanning
electron microscopy (SEM) images, and the dispersion rate
is also uniform.
Munir et al. [151] used the spark plasma sintering (SPS)
technique to fabricate TMCs reinforced with MWCNTs. Dif-
ferent concentrations (0.5 wt% and 1.0 wt%) of MWCNTs
were scattered into the Ti matrix by high energy ball mill-
ing (HEBM) and solution ball milling (SBM) method. The
strength of MWCNTs in composites was notably reduced,
owing to the formation of agglomeration. To make use of the
remarkable mechanical properties of MWCNTs, it is essen-
tial to prevent the damage that occurs during hybridization
processing.
Chen et al. [152] found that CNTs are uniformly distrib-
uted in the copper matrix by a novel mixing process and
spark plasma sintering (SPS) technique. The yield strength
of the composite with 2 vol % nickel (Ni) coated CNTs has
554 MPa, which was significantly increased when compared
with pure copper. The approximate interface shear strength
in Ni-CNTs/Cu composite is 179 MPa which is higher than
the shear strength of the matrix.
Salimi et al. [153] adopted an accumulative roll-bonding
to disperse CNTs in aluminum alloy. The process effectively
produced a composite microstructure embedded in an ultra-
fine grained aluminum matrix with multi-walled carbon
nanotubes. A fine grain structure of the matrix is obtained
when the rolling process is done frequently. With more than
30 walls, carbon nanotubes readily sustained four roll-bond-
ing operations and retained their multi-walled structure in
the composite.
Li et al. [154] found that when the content of vapor-
grown carbon fiber/graphite (VGCF/Gr) reinforcements
was increased, there is a slow improvement in grain refine-
ment, making the yield strength higher. The yield strength
and tensile strength of Ti—0.4 wt% VGCF were escalated
40.4% and 11.4% when compared with pure Ti simultane-
ously 30.5% and 2.1% for Ti—0.4 wt% Gr. The VGCF has a
tremendous strengthening effect compared to graphite and
results showed that VGCF could be an attractive reinforce-
ment for future applications in high-performance Ti matrix
composites.
Junhui et al. [155] reported that mechanical milling
accompanied with spark plasma sintering (SPS) techniques
is used for the development of molybdenum-carbon nano-
tube/copper (Mo-CNT/Cu) composites. Molybdenum/
carbon nanotubes composition of 2.5 vol% to 7.5 vol%
showed a homogeneous dispersion in the copper matrix and
obtained good thermal properties compared to pure cop-
per (Cu). Excessive molybdenum/carbon nanotubes content
resulted in a non-uniform distribution of Mo-CNTs within
the matrix and consequently decreased the mechanical prop-
erty and thermal conductivity. Although 5 vol % Mo-CNTs
showed a higher tensile strength value as compared with
ordinary CNTs sample.
Singhal et al. [156] found that amino-functional multi-
walled carbon nanotubes (fCNTs) of 1.5 wt% were dis-
tributed in aluminum powder by high-energy ball milling
technique and obtained enhanced mechanical property. The
composites strength is increased due to the formation of a
strong layer of aluminum carbide ­(Al4C3) and simultane-
ously provides improved load transfer from Al matrix to
fCNTs. The microhardness of aluminium matrix reinforced
with fCNTs processed from 40 h of ball-milled showed a
significant improvement in hardness about 300 kg/mm2
when compared with pure aluminium composites of hard-
ness 120 kg/mm2.
Cao et al. [157] reported that catalytic pyrolysis of poly-
ethylene glycol (PEG) were obtained to promote the homo-
geneous distribution of CNTs in aluminum powders provid-
ing materials for manufacturing aluminum reinforced carbon
nanotubes through the powder metallurgy method. However,
homogeneous dispersion of CNTs in Al nanoflake powders
is obtained by the pyrolysis of PEG and enhanced compres-
sive strength in the composite.
Hanizam et al. [158] found that multi-walled carbon
nanotubes—aluminum alloy (A356) composites are appro-
priate for mass production and complex design making. The
composites were fabricated by mechanical stir casting, fol-
lowed by thixoforming and modified by (MT6) heat treat-
ment. The Field Emission Scanning Electron Microscope
(FESEM) images revealed that MWCNT–A356 composite
was successfully fabricated using liquid metallurgy (LM)
processing and obtained the homogeneous dispersion.
Shi-Ying et al. [159] reported that magnesium matrix
nanocomposite reinforced with carbon nanotubes (CNTs/
AZ91D) was produced by mechanical stirring and ultrasonic
dispersion processing. The microstructural shows that high-
intensity ultrasonic waves can be used to distribute CNTs
uniformly in the matrix. The mechanical properties can be
improved considerably, and at the same time, the nanocom-
posites strength and ductility are improved. Mechanical
properties such as tensile strength, yield strength and elon-
gation were significantly increased by 22%, 21%, and 42%
in mould casting.
Lopez et al. [160] found that a uniform dispersion and
good interfacial bonding are obtained by incorporating
CNTs in silica coating by sol–gel method, leading to a tre-
mendous increase in the coating sample’s hardness. Due to
13

the low temperature set up, a well dense with no impairment
in magnesium alloy is accomplished. The toughness in the
coating was significantly improved due to the inclusion of
CNTs.
Kim et al. [161] reported that carbon nanotube reinforced
aluminum composites were fabricated with a better disper-
sion rate using the spark plasma sintering (SPS) and hot
pressing (HP) method. The best dispersion condition is
obtained by mixing aluminum powder after acid treatment
and performing ultra-sonication for 20 min. The application
of carbon nanotubes to composite materials increases the
durability and hardness of the materials. Due to the evo-
lution of aluminum carbide (­ Al4C3), the hardness tends to
decrease and increasing the rate of wear.
Larianovsky et al. [162] found that a short period of
solidification during the high pressure die casting (HPDC)
process prevents damage in CNTs structures and aluminum
carbide formation at combined CNT/Aluminium. Carbon
nanotube reinforced aluminum (Al-CNTs) composites
showed improved strength relative to pure aluminum.
Li et al. [163] adopted a novel method to fabricate mag-
nesium matrix composite reinforced by CNTs–Al2O3 hybrid
reinforcement. The 8 wt% nickel (Ni) combined with CNTs
have a high yield strength with fine microstructure and the
corresponding CNTs–Al2O3 hybrid reinforcements are good
enough for strengthening the Mg matrix. The distribution
of CNTs in Mg matrix composites was found homogeneous
with well-bonded structure. Table 11 shows the mechanical
properties of magnesium composite with a different weight
content of CNTs.
Munir et al. [164] found that mechanical properties of
the titanium-multiwalled carbon nanotube (Ti-MWCNT)
composite combined with in situ TiC with high energy ball
milling (HEBM) technique has substantially enhanced. The
analysis revealed that multi-walled carbon nanotubes have
adequate capacity to withstand stress in the composite.
Anzawa et al. [165] reported that to prevent titanium car-
bide formation in the interface between CNT and titanium
matrix, silicon was sublimated to 1673 K. It was then hold
up with a 10–15 nm diameter MWCNT. The hybridization
process makes CNTs spread on the surface and distributed
uniformly. The maximum tensile strength of its matrix was
Table 11  Mechanical properties Composite with different wt% CNT
of magnesium composite with
a different weight content of
CNTs Pure Mg
1 wt% CNTs–Al2O3/Mg composites
2 wt% CNTs–Al2O3/Mg composites
4 wt% CNTs–Al2O3/Mg composites
8 wt% CNTs–Al2O3/Mg composites
13
International Nano Letters
1.5 times of its matrix. A high-strength CNT composite tita-
nium alloy was produced by the hybridization process.
Stein et al. [166] adopted a powder metallurgical process
to prepare high-performance aluminum alloy composites
reinforced by CNTs. Homogeneous dispersion of CNT in
the matrix has been achieved. The corresponding composite
material, which contains 2.0 wt% CNTs, shows increased
elastic modulus, yield strength, and ultimate tensile strength
by 5%, 9%, and 15% as compared to pure aluminum alloy
manufactured under the same conditions.
Trinh et al. [167] reported that a high-energy ball milling
process (HEBM) was adopted to prepare composite pow-
ders (aluminum and copper) and then combined by sintering
and hot isostatic pressing (HIP) techniques. The specimens
showed a homogeneous dispersion of CNTs with CNT con-
tent up to 1 wt% in the aluminum–copper (Al–Cu) matrix,
and a higher content of CNT (1.5 wt%) leads to cluster for-
mation in the matrix. The microhardness of specimens con-
taining 1 wt% CNT processed by vacuum sintering and hot
isostatic pressing (HIP) increased by a factor of 1.9 and 2.1
relative to specimens without CNTs sintered by the same
method.
Merino et al. [11] implemented a new route known as the
sandwich technique to produce enriched carbon nanotubes
reinforced metal matrix composites. The developed compos-
ite showed a strong interface bonding between magnesium
layers and MWCNTs. The composites showed enhanced
mechanical properties due to the excellent dispersion and
alignment of MWCNTs, which allowed a good transfer of
load from the matrix. Hence sandwich technique enables the
manufacture of MMCs with enhanced mechanical properties
in bulk and small scale.
Salama et al. [168] reported that the carbon nanotube
reinforced aluminum (Al/CNT) composites have been pro-
posed as a single matrix (SM) and dual matrix (DM). The
SM and DM composites were produced by dispersing CNTs
into powders of aluminum and incorporating SM Al/CNT
powders in a secondary matrix soft aluminum. DM com-
posite with the CNT content (1 wt% and 2.5 wt%) showed
an increment in ductility of 14.8% compared with SM. The
high energy ball milling (HEBM) is a promising technique
for the production of dual matrix (DM) composites.
Tensile strength Elastic modulus Reference
(MPa) (× ­105 N/mm2)
189.4 ± 2 0.35 ± 0.01 Li et al. [163]
208.9 ± 1 0.36 ± 0.01
216.6 ± 3 0.38 ± 0.02
229.5 ± 4 0.46 ± 0.03
208.1 ± 2 0.40 ± 0.01
International Nano Letters
Prater [169] investigated the rapid tool wear and process
parameters between the welding tool and the composites
using friction stir welding (FSW). Aluminum–Lithium
(Al—Li 2195) alloys showed enhanced mechanical proper-
ties by using FSW technique. Using an ­L27 orthogonal Tagu-
chi array with three factors (rotation rate, transverse speed
and length of weld) was considered to determine the wear.
Ferreira et al. [170] reported that magnetic alu-
minum–zinc–silicon matrix composites (Al–Zn–Si) rein-
forced with nanomagnetic iron oxide (­ Fe3O4) is processed
through the Sinter-Forging method. The aluminum powder
was mixed with zinc (5 wt%) and silicon (5 wt%) by ther-
momechanical doping. The composites’ mechanical proper-
ties are enhanced, and the Sinter-Forging technique exhibits
that it is an economical way to manufacture the composites.
Hence the aluminum-metal matrix composites reinforced
with nanographene flakes and iron oxide ­(Fe3O4) are suit-
able for aerospace applications.
Rawal [52] reported that the processing methods mainly
used in the development of MMCs are (1) high-pressure
diffusion bonding, (2) casting and (3) powder metallurgy
techniques. The quality and affordability of continuously
improved MMCs remains a significant barrier to insertion.
The use of discontinuously reinforced aluminum (DRA) in
various sectors such as automobile and aviation industries
and simultaneously made DRA metal matrix composite
affordable for spacecraft applications such as electronic
packaging.
Table 12  Agglomeration in CNT/MMCs
Metal matrix type Processing techniques
Aluminum Ball milling
Aluminum Ball milling with nano dispersion
Aluminum Ball milling with Sonication
2024Al matrix Cold isostatic with hot pressing
Magnesium Hot isostatic pressing
AZ91 alloy + Mg Melt stirring with high-pressure die
casting
Copper Ultrasonic cleaning with particles
composite system and spark plasma
sintering
Aluminum– Spray drying
silicon alloy
powders
Copper Melt stirring
Challenges in the fabrication of CNT
reinforced MMCs
Rubel et al. [171] reported that due to the improper pro-
duction techniques and chemical process, agglomerates
tend to form in CNT. Hence these results in poor disper-
sion of CNT in MMCs and also damage the texture in
composites. The formation of clusters in CNT affects the
mechanical properties, machinability as well as hardness.
Table 12 shows the existence of agglomeration in CNT/
MMCs. However, a uniform dispersion without the forma-
tion of agglomeration in Al matrix is found in ultrasonic
and ball milling techniques.
Neubauer et al. [16] reported that the selection of raw
materials must be evaluated based on the quality and other
features, including purity level. Dispersion of carbon
nanotubes in metal matrix composites, surface coating of
carbon nanotubes in the matrix, fabrication of composites
includes solid state and liquid state processing, Carbon
nanotubes alignment in composites, Design consideration
between filler and the matrix.
However, some novel techniques adopted to overcome
these challenges such as high-energy ball milling method
can be employed to obtain a uniform dispersion of CNT
in the matrix and reduce agglomeration by varying the
milling time. By applying surfactants, it is easy to dis-
perse CNT in water. The electroless method and molecular
CNT with different Existence of agglomeration Reference
weight and volume
percentage
2 wt% Occurrence of agglomeration at the Rubel et al. [171]
initial stage of milling
0.8, 1.6 vol% Formation of agglomeration is
observed
2 wt% Formation of porosity and agglomera-
tion is observed
1 wt% Very less formation of agglomeration,
simultaneously tensile strength and
elastic modulus increased
1, 2 wt% Agglomeration exists
0.1, 0.5, 1 wt% Agglomerates are observed with a
size of 2 μm at 1wt%
5, 10 wt% Presence of agglomerates observed
5, 10 wt% A part of CNT surface damage
appeared in 10wt% and existence of
agglomerates is observed
0.1 wt% Presence of agglomerates is observed
in raw MWCNT through micro-
graphs
13

level mixing process can be used in the surface coating to
purify the CNTs. Pressing and sintering techniques are
well suitable if the CNT has less percentage of content
in the matrix. In solid-state or liquid state processing by
using unidirectional pressure in hot pressing, a proper
alignment is achieved. Perhaps the CNT can be used in
specific applications with a target on their properties.
Conclusion
The importance of carbon nanotubes reinforced metal
matrix composites, processing techniques, properties of
various alloys and utilization of these alloys in aerospace
and defense sectors are discussed. The utilization of carbon
nanotubes in the aviation industry and their properties are
highlighted. The challenges faced during the fabrication of
carbon nanotubes reinforced metal matrix composites are
reported in this review. The challenges in the aerospace and
defense sectors are also presented. Previous work done in
the fabrication of CNT reinforced MMCs are extensively
reviewed for the future direction of work.
During the consecutive period, many research works
have been carried out to improve the desired properties of
CNT reinforced MMCs by different processing techniques.
Although, the CNT reinforced MMCs are limited in certain
applications due to poor distribution of CNT in the matrix,
formation of agglomeration, repair mechanism and to pro-
duce bulk composites.
Based on previous research work conducted, a novel tech-
nique spark plasma sintering, hot pressing, and powder met-
allurgy route combined with friction stir processing showed
a significant improvement in the homogeneous dispersion
of CNTs in metal matrix composites and interfacial bonding
strength between them. A new method solution assisted wet
mixing technique is developed to increase the load transfer
and strength in Al/CNT composites. To determine homo-
geneous dispersion of carbon nanotube in the composites,
hybrid reinforcement is a good choice and structural stabil-
ity is also significantly improved. Sinter-Forging techniques
are adopted for an economical way of producing CNT rein-
forced metal matrix composites with optimistic character-
istics. Sandwich techniques are well suitable for bulk scale
and large scale productions. Flake powder metallurgy tech-
nique showed significant progress in the better distribution
of CNTs in composites.
Thus to maintain nanoscale properties in large space
shuttle components and armor vehicles, the biggest chal-
lenge is to incorporate high volume content of CNTs in
composites to retain the mechanical properties. Although,
some of the factors to be considered in effective utilization
of CNT-MMCs to achieve the desired requirement of vari-
ous industries for future perspective. Since CNTs diameter
13
International Nano Letters
is in nanometer, a special attention is needed to increase
the density of CNTs during synthesis. Repair mechanism
and tribological characteristics investigation of CNT-MMCs
need attention in sufficient manner. More investigation and
studies are needed to produce CNT-MMCs in large volume
with a consideration of cost effectiveness. Besides this, pow-
der metallurgy routes are implemented to fabricate CNT
reinforced MMCs in an effective manner, whether sandwich
technique, Bc equal-channel angular extrusion (ECAP) and
sinter-forging techniques can produce composites with large
surface volume are to be analyzed.
Hence further attention is needed in fabrication methods
to produce a component with a large surface area with cost-
effectiveness to build a strong foundation of advanced mate-
rials in defense and aerospace sectors. Hence carbon nano-
tube reinforced metal matrix composites will be promising
advanced composites in making futuristic superior strength
components with attractive properties and accomplish the
elevated vision of defense and aerospace industries.
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