Professional Documents
Culture Documents
Volume 1
ENCYCLOPEDIA OF MATERIALS:
COMPOSITES
EDITOR IN CHIEF
Dermot Brabazon
I-Form, Advanced Manufacturing Research Centre, and Advanced Processing Technology
Research Centre, School of Mechanical and Manufacturing Engineering,
Dublin City University, Dublin, Ireland
Volume 1
Section Editors
Section 1: Metal Matrix Composite Materials, Edited by Manoj Gupta
Section 2: Polymer Matrix Composite Materials, Edited by Dermot Brabazon
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ISBN 978-0-12-819724-0
.
CONTENTS OF VOLUME 1
Contents of Volume 1 v
Preface xix
VOLUME 1
v
vi Contents of Volume 1
Metal Matrix Composites for Automotive Components in Depth Case Study: Development
of Automotive Brake Disc
Nanang Fatchurrohman and Shamsuddin Sulaiman 540
Application of Metal Matrix Composites in Non-Structural Applications
Mubarak Ali M, Mohamed Thariq, Vishwesh Dikshit, and Bhudolia S Kumar 557
xi
xii List of Contributors for Volume 1
Section Editors
Manoj Gupta, Section 1: Metal Matrix Composite Materials
Department of Mechanical Engineering, NUS, Singapore
xvii
PREFACE
This is the first Encyclopedia of Materials: Composites published by Elsevier which presents a vast and widely encompassing content in
the area of composite materials science and engineering. Composite materials have become even more important and ubiquitous
over the recent decades due to the many advantages that they can provide over single monolithic materials. This includes
improvements in the properties such as the physical, electrical, chemical, optical and magnetic properties which can be achieved by
combining two or more materials.
The two main types of composites, Metal and Polymer matrix based, are presented in detail within Sections 1 and 2 respectively
while Ceramic matrix composites are presented in Section 3. Smart composites which is an area that is growing fast with increasing
industrial relevance is covered in Section 4. Assessing the properties of composite materials thereby enabling their application is a
crucial aspect of composite materials development and usage. As such, Section 5 presents the testing methods used and property
results from the testing of composite materials. The design of composite materials is covered in Section 6. The recyclability and
sustainability of materials used in products is an ever more important topic. There are some challenges to achieve well the
recyclability of composite constructs. The Encyclopedia presented two Sections covering this one (Section 7) covering nature based
composites and another covering the life cycle analysis of composite materials (Section 8). In the last section of the Encyclopedia,
Section 9 covers how to join composite materials together and with more conventional monolithic materials.
As an Encyclopedia, these sections were prepared to be the primary central source of background knowledge for undergraduate,
postgraduate and researchers studying or working with composites. The audience of this work covers both academic and industrial
researchers. In todays’ composite materials market, engineers, architects, and even policy makers, need reference literature where to
find definitions, concepts and state-of-the-art knowledge. As such this Encyclopedia will be an invaluable reference for engineers,
architects, scientists, and policy makers.
Each section contains articles written by world experts in their area. As well as providing the latest background information, the
state of the art in the niche areas is presented in the individual articles. A particular concern in preparing these articles by the
authors and Section editors was to make the content as accessible as possible to the reader. This is important given the multi-
disciplinary nature of people working on the development and implementation of composite materials.
I take this opportunity to thank the 337 authors from across the world who have contributed the 171 articles to this
Encyclopedia. It has been enjoyable to work with you are encouraging to see your expertise, interest and desire to help others from
your contribution. With the many co-authored articles, there has been extensive collaboration which has resulted in a more
informed and well-presented Encyclopedia content for the reader.
I am indebted also to the members of the Editorial team who have worked many long hours over the last couple of years to provide
feedback and iterate on articles with the authors. The Editorial team have collectively many years of expertise working in their research
areas. This team was formed via a variety networking events including conferences such as ESAFORM and Global Conference on
Nanomaterial Forming (Manoj Gupta, Robertt Valente, Antonella Astarita), EU research projects and COST Actions (Fatima Zivic and
Eva Maria Pellicer), and via other Dublin City University and sustainable engineering networking events (Mohamed El Mansori and
Lorna Fitzsimons). I thank the Elsevier Major Reference Works team who supported in a professional manner the compiling of this
work. In particular, I thank Laura Jackson, Sajana P K, and Ruth Rhodes for their direction and support throughout the preparation of
this Encyclopedia.
Dermot Brabazon
May 2021
xix
Introduction to Metal Matrix Composite Materials: An Introduction
Manoj Gupta, National University of Singapore, Singapore
r 2021 Elsevier Inc. All rights reserved.
Introducing Composites
Composite refers to a material that is an outcome of unification of two different class of materials (Fig. 1) (Ceschini et al., 2016;
Gupta and Sharon, 2011). To note that composites were used in making bricks in prehistoric times and more importantly by
nature in providing functionality to both plants and animals including humans. The keen observations made by humans led to
development of modern composites including MMCs.
Composites can traditionally be classified using two approaches:
(1) Matrix based.
(2) Reinforcement based.
Schematics of these approaches to classify composites are shown in Figs. 2 and 3, respectively. For matrix-based classifications,
there may be other matrices such as Carbon matrix but they are more specialized types and do not come under mainstream
composites.
Based on reinforcements, the composites can be classified as (see Fig. 4):
Metal matrix composites (MMCs) represent conscious unification of metallic matrix and at least one reinforcement. The rein-
forcement can be (Ceschini et al., 2016; Gupta and Sharon, 2011; Lloyd, 1994; Ibrahim et al., 1991; Jayalakshmi and Gupta, 2015):
(1) Metallic.
(2) Ceramic (oxides, carbides, nitrides, borides).
(3) Intermetallic.
(4) Carbon based (CNT, graphene, buckyball, graphene oxide).
(5) Hollow (cenospheres, metal or ceramic based).
(6) Hybrid (combination of above and combination of length scales).
(7) Amorphous.
(8) Multicomponent alloys.
Most commonly used metallic matrices include but not limited to the following:
Parcle
Reinforced
Composites
Interconnected
Reinforcement
Based
Composites
The major (not limited to) matrix and reinforcement related factors that govern the end properties of MMCs are shown in
Figs. 10 and 11, respectively (Ceschini et al., 2016; Gupta and Sharon, 2011; Lloyd, 1994; Ibrahim et al., 1991).
As indicated in Fig. 9, MMCs can primary processed using following economically viable routes (Lloyd, 1994; Ibrahim et al., 1991):
(1) Liquid phase methods.
(2) Solid phase methods.
(3) Two phase methods.
There are other methods that are being researched but those methods are still in the developmental stages for scalable and/or
economical production. The liquid, solid and two-phase methods are listed in Figs. 12–14.
Among the liquid phase methods, the one including ultrasonic probes/transmitters are relatively new developments that have
shown promising results.
4 Introduction to Metal Matrix Composite Materials: An Introduction
Liquid Phase
Processing
Fig. 12 Most commonly used/researched methods to synthesize MMCs using liquid phase processing.
Among powder metallurgy methods, use of microwave sintering (Gupta and Leong, 2007), spark plasma sintering (Azarniya
et al., 2017), flake powder metallurgy (Xu et al., 2017), molecular level mixing (Bakshi et al., 2010) and friction stir processing
(Eskandari et al., 2016) are relatively new processes with significant potential.
Two phase methods probably were most exciting from metallurgical point of view, however, their utility in industrial
processing is limited. Disintegrated melt deposition technique is the latest process in this category with potential of scalability at a
very low equipment and infrastructural costs.
6 Introduction to Metal Matrix Composite Materials: An Introduction
Solid Phase
Processing
Fig. 13 Most commonly used/researched methods to synthesize MMCs using solid phase processing.
Two Phase
Processing
Spray
Disintegrated
Rheocasng Atomizaon and Osprey Process
Melt Deposion
Deposion
Fig. 14 Most commonly used/researched methods to synthesize MMCs using two phase processing.
Secondary
Processing
Techniques
Severe Plasc
Rolling Forging Extrusion
Deformaon
Severe Plasc
Deformaon
Techniques
Depending on the end application, at times the MMC billets are also secondary processed to further enhance their micro-
structural characteristics and properties. Common secondary processing techniques are indicated in Fig. 15.
In more recent times, efforts are continuously made to significantly enhance the properties of MMCs using severe plastic defor-
mation methods. Some of the promising methods sever plastic deformation processes used on bulk materials are listed in Fig. 16.
Like other structural materials, MMCs are used where certain enhanced functionalities from metallic materials is expected in end
applications due to the more demanding nature of emerging end applications. Most commonly investigated properties where
enhancement is expected include (Ceschini et al., 2016; Gupta and Sharon, 2011; Lloyd, 1994; Ibrahim et al., 1991):
Introduction to Metal Matrix Composite Materials: An Introduction 7
Joining Methods
Fusion Welding Fricon Sr Welding Explosive Welding Diffusion Bonding Brazing Soldering
Vacuum Brazing
Ultrasonic Assisted
A detailed analysis of these properties can be found elsewhere in this encyclopedia and will not be discussed here.
For industrial applications, joining of MMCs with MMCs or other metallic materials is required. Welding is one of the common
practice for the same. Different joining methods that have evolved and used are indicated in Fig. 17 (Ellis, 1996; Prater, 2011).
More recent development in joining of composites can be referred to in another article in this encyclopedia.
Machining is an important operation before a part is assembled into a device. Machining is done on both the cast and wrought
parts to different extents. Conventional machining processes such as turning, milling, drilling and wire cutting (EDM) are used for
machining MMCs (Lane, 1992; Gururaja et al., 2013). As traditional MMCs are reinforced with ceramic reinforcements which are
typically harder than materials used for making conventional tools (e.g. tool steels), the wear or deterioration of tools increases
faster affecting the surface characteristics of material that is machined. The problem is more severe when the micron and higher
length scale ceramic reinforcements are used as they can be loaded to a higher extent. Similarly, reduction in particle diameter also
assist in reducing tool wear and in that context, it is anticipated that nano-composites will perform better than microcomposites
(Lane, 1992). Diamond coated tools in that respect display better machining performance.
While investigating a machining process, researchers typically focus and optimize on the following parameters (Gururaja et al., 2013):
(1) Workpiece material: Nature of metallic matrix and reinforcement associated variables.
(2) Type of tool used: Polycrystalline diamond tools are most favored.
8 Introduction to Metal Matrix Composite Materials: An Introduction
Surface
Protecon
Methods
Surface
Painng Coang
Treatment
Surface
Spray Electroplang
Hardening
Electroless Anodic
Electrostac
Plang Oxidaon
Chemical
Coang
Hot Dipping
Thermal
Spraying
Metallic
Cementaon
It was emphasized by researchers that due to above mentioned factors and complexity of machining processes, detailed
optimization of the parameters is important to ensure minimal tool wear and to realize desirable surface finish. Latest and detailed
information on high performance machining of MMCs can be referred to in another article on machining in this encyclopedia in
the Metal Matrix Composites section.
Surface protection of metallic surfaces is important and MMCs are no exception. The common purposes of providing surface
protection include:
Hydroelectric
power
Sports
plants/Power
transmission lines
Transportaon
Consumer (Automobiles,
Electronics trains and
marime)
Defense
Various types under these categories are shown in Fig. 18 and discussed in details elsewhere in this Encyclopedia.
Metal matrix composites are actively been looked into many structural and non-structural applications and most prominent of
them are indicated in Fig. 19 (Ceschini et al., 2016; Gupta and Sharon, 2011; Lloyd, 1994; Ibrahim et al., 1991). Main physical,
thermal, mechanical and surface properties that are actively looked for these applications are:
Most of the abovementioned properties can be easily tailored and realized using MMC technology. Besides investigators are
looking into the possibility of using MMC technology in many other more specific applications which include and not restricted to
the following:
Active research in MMCs has almost spanned five decades and tremendous lessons are learnt on the fundamental principles
governing their microstructure and properties. Researchers have convincingly established the efficacy of many formulations at lab
scale and certain leading multinational companies have shown the capabilities to convert them into industrial products. However,
the issue of scalability to synthesize MMCs using liquid metallurgy based high volume production routes with microstructural
consistency is still a big issue for many countries for their widespread use. More involvement of industry is required to take these
highly tailorable and property specific materials to the next level.
10 Introduction to Metal Matrix Composite Materials: An Introduction
References
Ceschini, L., Dahle, A., Gupta, M., et al., 2016. Aluminum and Magnesium Metal Matrix Nanocomposites. Springer. (ISBN: 978-981-10-2680-5 (Print) 978-981-10-2681-2
(Online)).
Azarniya, A., Azarniya, A., Sovizi, S., et al., 2017. Physicomechanical properties of spark plasma sintered carbon nanotube-reinforced metal matrix nanocomposites. Progress in
Materials Science 90, 276–324.
Bakshi, S.R., Lahiri, D., Agarwal, A., 2010. Carbon nanotube reinforced metal matrix composites – A review. International Materials Reviews 55 (1), 41–64.
Ellis, M.B.D., 1996. Joining of Al-based metal matrix composites – A review. Materials and Manufacturing Processes 11 (1), 45–66. doi:10.1080/10426919608947460.
Eskandari, H., Taheri, R., Khodabakhshi, F., 2016. Friction-stir processing of an AA8026-TiB2-Al2O3 hybrid nanocomposite: Microstructural developments and mechanical
properties. Materials Science and Engineering A 660 (13), 84–96.
Gupta, M., Meenashisundaram, G.K., 2015. Insight into Designing Biocompatible Magnesium Alloys and Composites. Springer.
Gupta, M., Wong Wai Leong, E., 2007. Microwaves and Metals. Singapore: John Wiley and Sons (Asia) Pte Ltd, (ISBN: 978-0-470-82272-2; ISBN: 978-0-470-49417-2).
Gupta, M., Sharon, N.M.L., 2011. Magnesium, Magnesium Alloys and Magnesium Composites. John Wiley.
Gururaja, S., Ramulu, M., Pedersen, W., 2013. Machining of MMCs: A review. Machining Science and Technology: An International Journal 17 (1), 41–73.
Ibrahim, I., et al., 1991. Particulate reinforced metal matrix composites – A review. Journal of Materials Science 26 (5), 1137–1156.
Jayalakshmi, S., Gupta, M., 2015. Metallic Amorphous Alloy Reinforcements in Light Metal Matrices. Springer.
Lane, C., 1992. Machininability of aluminium composites as a function of matrix alloy and heat treatment. In Proceedings of the Machining of Composite Materials
Symposium. Chicago, IL: ASM Material Week.
Lloyd, D., 1994. Particle reinforced aluminium and magnesium matrix composites. International Materials Reviews 39 (1), 1–23.
Prater, T., 2011. Solid-state joining of metal matrix composites: A survey of challenges and potential solutions. Materials and Manufacturing Processes 26 (4), 636–648.
doi:10.1080/10426914.2010.492055.
Xu, R., Tan, Z.Q., Xiong, D.B., et al., 2017. Balanced strength and ductility in CNT/Al composites achieved by flake powder metallurgy via shift-speed ball milling. Composites
Part A: Applied Science and Manufacturing 96, 57–66.
Fundamentals of Metal Matrix Composites
Sankaranarayanan Seetharaman and Manoj Gupta, National University of Singapore, Singapore
r 2021 Elsevier Inc. All rights reserved.
Introduction
Metal matrix composites (MMCs) comprise of a continuous matrix of metallic alloys together with ceramic reinforcements, or metallic
phases (Clyne and Withers, 1995). They offer a wide range of opportunities in various applications such as automobile, power train,
aerospace, consumer electronics, packaging, and sports due to improved mechanical properties, wear resistance, creep resistance, damping
characteristics, and reduced thermal expansion characteristics (Sijpkes and Vergouwen, 2004; Kainer, 2006; Barrett, 2017) (Fig. 1).
Fig. 2 Shows some of the commonly used matrix materials which include aluminum, copper, magnesium, titanium, nickel,
steel whose properties are listed in Table 1. While MMCs based on aluminum, magnesium, and titanium alloys are the excellent
candidates for lightweight structures in automotive, aerospace, and defense applications (Adebisi et al., 2011; Jayalakshmi and
Gupta, 2015), MMCs based on steel, nickel, and copper alloys are highly recommended for tooling, heavy industries, and
electronic packaging, respectively.
In general, the reinforcement phases are hard and strong, and they are known to exhibit good thermal stability and Young’s
modulus. Hence, the inclusion of reinforcements can improve the performance of matrix material (Ashby, 2005; Callister and
Rethwisch, 2007). Some of the commonly used reinforcements are shown in Figure and their properties are listed in Table 2. Based
on the size and shape, reinforcements can be broadly classified into continuous and discontinuous reinforcement forms (Chawla
and Chawla, 2004). The most common continuous reinforcement are the carbon or ceramic fibers. As these fibers are brittle and
flaw sensitive, they are often provided protective coatings to avoid any unwanted chemical reactions and to improve the bonding/
wetting characteristics. The fiber reinforcements are also known to exhibit size effects (i.e., the strength of these fibers decreases as
the length increases), and they can be further classified into long or short fibers. Similarly, discontinuous reinforcement includes
ceramic and metallic particulates in the size range from few nanometers to few hundred micrometers which are known to develop
MMCs with isotropic properties (Chawla and Chawla, 2004; Kainer, 2006).
Based on the type of reinforcement, MMCs are classified into (1) fiber reinforced MMCs, (2) particle reinforced MMCs, and (3) multi-
layered laminates (Fig. 3). The fiber composites can be further classified as continuous and discontinuous fiber reinforced composites.
Fig. 1 (a) Turbofan made using MMC and (b) Structural component in F16 Falcon landing gear made using SiC monofibers reinforced Ti MMC.
Courtesy: Barrett, T., 2017. The Future of Metal Is in Matrix Composites. Available at: https://www.machinedesign.com/materials/article/21835569/
the-future-of-metal-is-in-matrix-composites. Sijpkes, T., Vergouwen, P., 2004. Composite materials for structural landing gear components. In: ERF
2004, 38. Available at: https://dspace-erf.nlr.nl/xmlui/bitstream/handle/20.500.11881/282/38_sijpkes.pdf?sequence=1&isAllowed=y.
Base matrix alloy Density (g/cc) Modulus (GPa) Yield strength (MPa) Ductility
Metal Crystal structure Density Melting point Thermal Thermal expansion Mohr Modulus
(g/cm3) (1C) conductivity coefficient hardness (GPa)
Particulate Composites
Particulate composites consist of a matrix reinforced by particles that are dispersed randomly or with a well-defined orientation.
Nanocomposites
In particulate composites. when one of the dimensions of the particulate reinforcement is less than 100 nm, the resulting
composite is referred to as nanocomposite. Recently, metal matrix composites containing nanoscale reinforcements are receiving
stupendous attention as the low volume dispersion of hard and strong reinforcing phases in nano-length scale contributes
significantly towards the strengthening of the matrix material. Unlike micron and sub-micron length scale reinforcement addition,
the efficient dispersion of nanoscale reinforcement improves the strength of matrix material without adversely affecting the
ductility (Goh et al., 2006b; Casati and Vedani, 2014; Gupta and Wong, 2015).
Laminate Composites
Composite laminates consist of multiple layers of sheet laminates made of the matrix and reinforcement materials stacked and
cemented in a specific pattern in order to achieve the desired strength. Based on the stacking sequence, the composite laminates are
classified into angle and cross-ply laminates which can be either symmetric, antisymmetric, or balanced. Fig. 4 shows the
construction of a lightweight laminated composite (0.16 kg) developed to replace the aluminum heat sink (0.29 kg) of printed
circuit boards.
A variety of methods can be employed in the fabrication of metal matrix composites and they can be broadly grouped under either
liquid or solid-state processing methods. Similarly, based on the nature of reinforcement addition, the processing methods can be
either ex-situ or in-situ processing.
14 Fundamentals of Metal Matrix Composites
Fig. 4 Lightweight laminated composite heat sink developed for printed circuit boards. Redrawn from Holz, J.M., Niemeyer, L., Puckett, D., 2000.
Composite-Material Heat Sink for Printed-Circuit Boards, Technical Support Package. GSC-14142. Goddard Space Flight Center. Available at:
https://www.techbriefs.com/component/content/article/tb/techbriefs/materials/6720.
Melt infiltration
Melt infiltration involves either spontaneous or forced infiltration of a liquid metal alloy into a porous preform containing fibers/
whiskers reinforcements upto 70 vol% (Kainer, 2006). The spontaneous infiltration is also known as pressure less infiltration in
which no external pressure or force is used to process MMCs based on Al–Si, Al–Mg, and Al–Zn alloys with better flowability.
However, the poor wettability between the matrix and the reinforcing phase slows down the fabrication process resulting in
undesirable reaction products at the interface. Several studies have reported an improvement in the wettability through activators
or processing in nitrogen atmosphere. In forced infiltration process, the infiltration of molten metal into the porous reinforcement
is achieved through the application of external pressure or by using mechanical force as shown below to overcome the issues
associated with poor wetting and adhesion characteristics.
Ultrasonic infiltration:
In this process, the pressure waves generated by ultrasonic vibrations assists in the acoustic cavitation and the collapse of bubbles
originating close to the molten metal helps in the penetration of molten metal into the reinforcement preform (Matsunaga et al.,
2007). Fig. 7 shows the ultrasonic infiltration experimental setup used to fabricated carbon fiber reinforced Al composite wires.
Fundamentals of Metal Matrix Composites 15
Fig. 5 Pressure die infiltration process. Redrawn from Garg, P., et al., 2019. Advance research progresses in aluminium matrixcomposites:
Manufacturing & applications. Journal of Materials Research and Technology. 8 (5), 4924-4939. doi:10.1016/j.jmrt.2019.06.028.
Fig. 6 Gas pressure infiltration. Redrawn from Garg, P., et al., 2019. Advance research progresses in aluminium matrixcomposites:
Manufacturing & applications. Journal of Materials Research and Technology. 8 (5), 4924-4939. doi:10.1016/j.jmrt.2019.06.028.
Fig. 7 Ultrasonic infiltration furnace set up. Reproduced from Matsunaga, T., et al., 2007. Fabrication of continuous carbon fiber-reinforced
aluminum-magnesium alloy composite wires using ultrasonic infiltration method. Composites Part A: Applied Science and Manufacturing. 38 (8),
1902-1911. doi:10.1016/j.compositesa.2007.03.007.
16 Fundamentals of Metal Matrix Composites
Fig. 8 Centrifugal infiltration setup and principle. From Sánchez, M., Rams, J., Ureña, A., 2010. Fabrication of aluminium composites reinforced with
carbon fibres by a centrifugal infiltration process. Composites Part A: Applied Science and Manufacturing. 41 (11), 1605-1611. doi:10.1016/j.compo-
sitesa.2010.07.014. Sánchez-Martínez, A., et al., 2016. Main process parameters for manufacturing open-cell Zn-22Al-2Cu foams by the centrifugal
infiltration route and mechanical properties. Materials and Design. 108, 494-500. doi:10.1016/j.matdes.2016.07.032.
Centrifugal infiltration:
In this process, the reinforcement is positioned inside a mold with long runners filled with molten metal which infiltrates the
preform under large rotational velocities or centrifugal forces which is given by:
1 2 2
Pc ¼ ro L ð1Þ
2
where, Pc ¼ pressure generated at the preform top surface during the rotation in centrifugal casting, p ¼ density of the molten
metal, o ¼ 2 pO/60 where O is rotational speed (rpm), L ¼ molten metal level from the rotational axis (Sánchez et al., 2010;
Sánchez-Martínez et al., 2016) (Fig. 8)
Squeeze casting:
Squeeze casting infiltration process is one of the widely used fabrication techniques for producing net shape MMCs with control
over shapes, chemistry, volume fraction and distribution of reinforcement (Uozumi et al., 2008). In squeeze casting, the molten
metal is forced into the preform and a pressure is applied until the solidification is complete. This method can be applied for both
the fibers and particles reinforced composites as the prefabricated fiber or particle preforms can be melt infiltrated and solidified
under pressure. To avoid damage to the preforms, the melt is first pressed into the preform at low pressure and then the pressure is
increased for solidification. Since the melt solidifies under very high pressure, the squeeze cast composites are free from the
common casting defects such as porosity and shrinkage cavities. As the duration of the infiltration is relatively short, the squeeze
casting method can be applied for reactive materials like magnesium (Jayalakshmi et al., 2006) (Fig. 10).
Based on the mode of pressure application, squeeze casting can be classified into direct and indirect squeeze casting. In direct
squeeze casting method, pressure for the infiltration of preforms is applied directly to the melt. However, in indirect squeeze
casting, the melt is pressed into the preform through a gate system. Although the tooling is relatively simple for direct squeeze
casting, the absence of gate system necessitates accurate determination of the melt volume. Another disadvantage is the presence of
oxide residue in the composite which are normally restricted by the gate in the indirect squeeze casting.
Fundamentals of Metal Matrix Composites 17
Fig. 9 Lorentz force infiltration setup. Reproduced from Andrews, R.M., Mortensen, A., 1991. Lorentz force infiltration of fibrous preforms.
Metallurgical Transactions A.22, 2903–2915. doi:10.1007/BF02650251.
Fig. 10 Squeeze casting. Redrawn from Garg, P., et al., 2019. Advance research progresses in aluminium matrixcomposites: Manufacturing &
applications. Journal of Materials Research and Technology. 8 (5), 4924–4939. doi:10.1016/j.jmrt.2019.06.028.
Stir casting
Stir casting or compo-casting is the most common and cost-effective method of producing composite materials (Kainer, 2006;
Tzamtzis et al., 2009). In this method, the reinforcement phase (fiber or particles) is mixed with the molten matrix metal by means
of mechanical or ultrasonic stirring. The molten composite slurry is then cast by conventional casting methods. The properties of
the MMCs produced using stir casting methods will depend on the processing parameters such as temperature of melt, stirring
speed, stirring duration, geometry of the stirrer and size of crucible which will affect the distribution of the reinforcements in the
matrix. The dispersed phases are also often coated with proper wetting agents to achieve better interfacial bonding with the matrix
material and to avoid any unwanted reaction and the dissolution of reinforcement at high temperatures. In case of particulate
reinforcement, careful attention must be paid to the dispersion of the particles as they tend to form agglomerates. In general, the
18 Fundamentals of Metal Matrix Composites
Fig. 11 Schematic of (a) mechanical stir casting and (b) ultrasonic stir casting.
proper selection of processing parameters such as melt temperature, stirring speed, duration, and stirrer geometry, etc., allows
the effective dispersion of particles (in the size range 5–100 mm) up to 30% by volume (Fig. 11).
Melt deposition
There are several deposition techniques available to produce metal matrix composites. While deposition methods like immersion
and electroplating, chemical vapor deposition (CVD), physical vapor deposition (PVD) are only used for fiber reinforced MMcs,
the spray and disintegrated melt deposition methods can be used for both the particle reinforced metal matrix composites
(Harrigan, 1998).
Immersion plating:
This method is applicable for continuous fiber reinforcement which are passed through baths of molten metal, slurry, sol, or
organometallic precursors.
Electroplating or electrodeposition:
In this method, the matrix metal coating is produced from a solution containing the ion of the desired material in the presence of
an electric current. As this process is carried out at moderate temperatures, this method offers less/no damage to the reinforcement
fibers. However, processing defects such as poor bonding and porosity are common for MMcs produced using this method. Also,
only limited alloy matrices can be processed using this method.
Spray deposition:
In spray deposition, reinforcements in the form of particles/whiskers are injected into the spray of molten metal, creating a
deposition layer on the substrate (Wood, 1997). The depositions are then densified by suitable post-processing techniques.
Similarly, for continuous fiber reinforcements, the molten matrix metal is sprayed onto the fibers with preferred orientation. In this
method, fiber alignment can be easily controlled and a relatively faster solidification rates can be achieved.
Fundamentals of Metal Matrix Composites 19
Fig. 12 Spray deposition. Redrawn from Garg, P., et al., 2019. Advance research progresses in aluminium matrixcomposites: Manufacturing &
applications. Journal of Materials Research and Technology. 8 (5), 4924–4939. doi:10.1016/j.jmrt.2019.06.028.
It is a promising method for producing particle reinforced MMCs. It involves spray techniques which are used to develop
monolithic alloys. Fig. 12 shows an example of the spray forming process in which a spray gun is used to atomize the molten
matrix metal into which the reinforcement particles are injected. The resulting metal matrix composite (about 97% dense) is then
subjected to scalping, consolidation, and secondary finishing processes to produce wrought composites. To facilitate the efficient
transfer of particle reinforcement, an optimum particle size and shape must be maintained.
Powder consolidation
In this method, the required amounts of matrix alloy and reinforcement powders are mixed to prepare a composite blend which is
then cold or hot compacted into a billet. The prepared green billet is then canned, degassed and sintered at temperature closer to
the solidus temperature of the matrix alloy (Sankaranarayanan and Gupta, 2015) (Fig. 14).
While this method can be effectively used for particle reinforced aluminum or magnesium composites, cold-pressing and sintering are
not preferred in case of long fiber reinforcement which are often damaged under the high pressure. Hence, for long continuous fibers, the
fiber tows are first infiltrated by dry matrix powder which is then followed by hot isostatic pressing (Gupta and Sharon, 2010).
Mechanical alloying
Mechanical alloying involves repeated cold welding, fracturing, and re-welding of powder particles in a high energy ball mill
(Suryanarayana, 2001). In this process, the frictional heat developed at the particle interface results in the local melting
and consolidation of powder particles. The composite powder mixture obtained from ball-milling is then densified using cold or
hot-pressing techniques (Sankaranarayanan and Gupta, 2015) (Fig. 15).
Due to the nature of high dislocation densities generated in this method and the homogenous distribution of reinforcing
constituents, this method can be effectively applied to develop a range of equilibrium/non-equilibrium alloys and composites
with excellent set of properties.
Fig. 13 Disintegrated melt deposition. Reproduced from Gupta, M., Wong, W.L.E., 2015. Magnesium-based nanocomposites: Lightweight
materials of the future. Materials Characterization.105, 30-46. doi:10.1016/j.matchar.2015.04.015.
alloy for a certain period in order to allow atomic diffusion and inter-particle bonding (Padmavathi et al., 2011; Slotwinski et al.,
2014). In most cases, the sintering of green powder compact also facilitates the microstructural recrystallization for strengthening
alongside densification and removal of residual lubricant (Fig. 16).
Fundamentals of Metal Matrix Composites 21
Fig. 16 Stages in sintering: Stage I: Particle bonding in green compact, Stage II: Growth of contact points into ‘necks’ and Stage III: final
microstructure showing grains and pores.
Diffusion bonding
Diffusion bonding is a solid-state technique used to process a wide variety of fiber reinforced MMCs. It involves the interdiffusion
of atoms at the mating surface between the matrix and reinforcement to cause chemical/mechanical bonding under the influence
of temperature and pressure (Fig. 18). Although the fiber orientation and volume fraction can be effectively controlled, the
processing time and cost are relatively high thus limiting its extended application.
Deformation processing
Fabrication methods based on mechanical deformation are highly applicable for metal-metal or layered metal composites. Fig. 19
illustrates the methodology of roll bonding process used to produce sheet metal composite laminates. Here, a two-phase alloy
22 Fundamentals of Metal Matrix Composites
Fig. 17 Schematic of microwave sintering and heat transfer principle. Modified from Penchal Reddy, M., et al., 2016. Microwave rapid sintering of al-
metal matrix composites: A review on the effect of reinforcements, microstructure and mechanical properties. Metals. doi:10.3390/met6070143.
Fig. 18 Schematic showing diffusion bonding process. Redrawn from Garg, P., et al., 2019. Advance research progresses in aluminium
matrixcomposites: Manufacturing & applications. Journal of Materials Research and Technology. 8 (5), 4924–4939. doi:10.1016/j.jmrt.2019.06.028.
material is subjected to mechanical deformation causing the minor phase to elongate and become fibrous within the matrix
(major phase). However, it should be noted that this method is limited to ductile two-phase materials in which the two phases
exhibit similar flow stresses pattern for co-deformation. Further, the deformation processed materials also require post-processing
heat treatments to reduce mechanical anisotropy.
In-Situ Processes
In-situ methods include processes based on liquid–gas, liquid–solid, liquid–liquid, and mixed salt reactions in which the chemical
reaction between reacting constituents leads to in-situ formation of reinforcement (Harrigan, 1998; Thein et al., 2009; Ghosh et al., 2010;
Fundamentals of Metal Matrix Composites 23
Fig. 19 Roll bonding process for making a laminated MMC. Reproduced from Khaledi, K., et al., 2018. Modeling of joining by plastic
deformation using a bonding interface finite element. International Journal of Solids and Structures. doi:10.1016/j.ijsolstr.2018.10.014.
Fig. 20 Self-propagating high temperature synthesis of MMCs. Redrawn from Garg, P., et al., 2019. Advance research progresses in aluminium
matrixcomposites: Manufacturing & applications. Journal of Materials Research and Technology. 8 (5), 4924–4939. doi:10.1016/j.jmrt.2019.06.028.
Jayalakshmi et al., 2013). Hence, a good understanding of reaction kinetics and thermodynamics is essential in order to obtain the
desirable end-products. Generally, the in-situ developed composites exhibit very fine and well dispersed reinforcement phases which
are stable and free from surface contaminants and has a coherent interface assisting in stronger bond between the reinforcement and the
matrix material.
One of the well-known examples of in-situ methods is the unidirectional solidification of eutectic alloy resulting in the
formation and distribution of fibers like phases in the matrix alloy (Livingston, 1974). Sometimes, it is also referred to as self-
propagating high temperature synthesis (SHS) when the reinforcing phases are produced by exothermic reaction between the
matrix constituents (Subrahmanyam and Vijayakumar, 1992; Mossino, 2004; Xiao et al., 2004) (Fig. 20). In these methods, the
characteristics of the reinforcing phases, especially the interfacial compatibility are controlled by the solidification rate which is
generally limited to B1–5 cm/h to maintain the temperature gradient for a stable growth front.
Additive Manufacturing
Laser-based additive manufacturing techniques such as selective laser melting and laser deposition were also used to fabricate
metal matrix composites based on Al, Ti, and Ni based matrix materials (Gu et al., 2012; Manfredi et al., 2014; Pouzet et al., 2016;
24 Fundamentals of Metal Matrix Composites
Fig. 21 Schematic of selective laser melting and laser deposition methods. Courtesy Benedyk, J.C., 2018. Additive manufacturing of aluminum
alloys: Augmenting or competing with traditional manufacturing? Light Metal Age.
Aboulkhair et al., 2019; Behera et al., 2019). These methods involved a high energy laser source to melt and deposit the powder
raw materials in a layer-by-layer fashion (Fig. 21). In most cases, the reinforcement phases are often developed in-situ due to the
chemical reaction between the powder raw materials (Banerjee et al., 2005; Attar et al., 2014a). On the other hand, the laser
processing of ex-situ prepared composite powder mixture was also investigated and it was found that the composite powder
preparation plays an important role in determining the end properties of the bulk composite (AlMangour et al., 2016, 2017a,b;
Famodimu, 2016).
Properties of MMCs
The end properties of composite materials are controlled by many variables including reinforcement form, volume fraction,
geometry, distribution, matrix/reinforcement interface, void content, and manufacturing process. The presence, amount, and
distribution of reinforcement influence the dislocation behavior and hence the physical and mechanical properties of the com-
posites. In addition to physical and mechanical properties, the reinforcement also influences other material properties such as the
wear resistance and damping capacity. The mechanical properties of MMCs are not only affected by the properties of matrix and
reinforcing materials, but also by the interfacial characteristics and it is well established that the week bonding between them
generally worsen the properties of MMCs. The following section will provide an overview of the properties of metal matrix
composites.
where,
I believe your eyes and ears will be opened too late. You
will then see, to your cost, that admonitions (called scoldings)
were the highest compliment I could pay a man in your
situation, by endeavouring to raise his mind to the altitude
necessary to exist (one may say) in a wreck of worlds. If you
were so uneasy at Jôon, how will your nerves bear what you
will be doomed to see? but, when this time comes, no more
advice from me to you or any one: let all pick their way, and
abide by the consequences. Words are nothing: the hearts of
men must be cleansed of all the vain idle stuff they now
cherish as a sort of safeguard or escape-boat to evils of all
kind. If the naked savage, who has the feelings of a man, is
not in high favour with the Almighty, and placed in a higher
situation (if he continues to do his duty) than the educated
mylord, the pedant, the gentleman, as it is called, without
either conscience, talent, or money, I know nothing; and you
may reproach me hereafter in the harshest possible terms.
It is a very mean spirit which fears obligation: we are under
obligations of the most serious nature every day to the horse,
the ass, the cow, &c. All the stuff persons now call spirit are
the vulgar ideas of the lowest and least philosophical of
human beings. What should I think of my deserted self, were I
to constantly talk to Logmagi of obligation? I am proud to
acknowledge all I owe to his zeal and obedience.
This was the last letter I ever received from her ladyship. She died
in June following, Ἄταφος, ἄκλαυτος, ἄφιλος, ἀνυμεναιος[42]
everybody being in ignorance of her approaching end, except the
servants immediately about her. She had no Frank or European near
her, and Lunardi, who was coming out to her from Leghorn, reached
Beyrout unfortunately too late. “The news[43] of her death was
conveyed to Beyrout in a few hours, and the English consul, Mr.
Moore, and the Rev. Mr. Thomson, an American missionary, went to
Jôon, to bury her. Her emaciated corpse was interred in the same
grave where the body of Captain Loustaunau had been placed,
some years before, in her own garden: this was according to her
desire, expressed to Logmagi before her death.” Reports were
spread that her furniture, plate, and other valuables, had been
plundered, and much stress was laid on the circumstance that not
even her watch was found: but she had no watch, and only a dozen
and a half of silver spoons and forks. Fatôom, it is said, died two
days before her mistress.
FOOTNOTES:
[34] See “Robinson’s Three Years in the East,” note xviii., page
125, vol. Palestine.
[35] This letter, and the letter to Lord Brougham, were intended by
Lady Hester Stanhope for publication in the newspapers
conjointly with the correspondence about her debts: but the
space, which so much matter would have occupied, rendered it
necessary to leave them out.
[36] The adoption of the words “Sir Baron, Sir Count,” at the
beginning of letters, may appear to the reader quaint and
ridiculous; but these expressions are only verbal translations of
“Monsieur le Baron,” “Monsieur le Comte,” and less abrupt than
plain “Baron,” “Count.” Abroad, the prefix “Dear” is not so lightly
attached to a name as it is in England. I recollect, some years
ago, an Italian gentleman, Signor Guiseppe Celi, proprietor of a
marine villa on the Island of Palmaria, in the Gulf of Spezzia, to
have shown me a letter he had received from an English
gentleman, who had tenanted his house for some months, and
between whom and himself, as it appeared, there existed a
tolerable degree of intimacy, and his asking me what I thought of
Mr. B.’s addressing him Caro Signore. The wary Italian seemed to
imagine it was a term of friendship, to which he was not entitled,
and fancied he was about to be wheedled out of something; he
could not imagine it proceeded from the writer’s good nature.
Chi vi carezza più che non suole,
O vi ha ingannato, o ingannarvi vuole.
[37] Lady Hester Stanhope was deceived in her prediction. Shibly
el Arriàn went over to the Pasha, and, by a letter received from
Lady Hester, dated March, 1839, she informed me he was
employed in raising troops among his dependants and friends
against his former allies.
[38] A Gallicism, meaning by the next steamer.
[39] The yazjees, or government secretaries, are men of the
same presumed respectability in Syrian towns as bankers,
solicitors, or professional men are with us; yet, in cases of
malversation of the public money, often, indeed, on mere
suspicion of peculation, they are punished with the lash, or by
bastinado. Woe to an exchequer defaulter under Ibrahim Pasha!
[40] Memoirs of Sir W. K. by Lady Knighton. Who shall say what
Lady Hester meant by “Love is not amongst them?”
[41] Diary of the Times of George IV.
[42] Soph. Antig., l. 888.
[43] The lines with inverted commas I have copied from the
newspapers, not having been able to obtain more authentic
information; but I much doubt if Lady Hester ever expressed any
desire to be interred in Loustaunau’s grave.
[44]
Quis enim virtutem amplectitur ipsam,
Præmia si tollas?
[45] “A group of Bedouins were disputing respecting the sanity of
Lady Hester Stanhope; one party strenuously maintaining that it
was impossible a lady so charitable, so munificent, could be
otherwise than in full possession of her faculties; their opponents
alleging that her assimilating herself to the Virgin Mary, her
anticipated entry with our Saviour into Jerusalem, and other
vagaries attributed to her, were proofs to the contrary. An old man
with a white beard called for silence (a call from the aged amidst
the Arabs seldom made in vain.) ‘She is mad,’ said he; and,
lowering his voice to a whisper, as if fearing lest such an outrage
against established custom should spread beyond his circle, he
added, ‘for she puts sugar in her coffee.’”—Travels in Arabia, by
Lieutenant Welsted, F.A.S. v. ii. p. 69.
THE END.