MODULE-4

Metal Matrix Composites

Metal matrix composites consist of a metal or an alloy as the continuous matrix and a
reinforcement that can be particle, short fiber or whisker, or continuous fiber.
Types of Metal Matrix Composites
There are three kinds of metal matrix composites (MMCs):
• Particle reinforced MMCs
• Short fiber or whisker reinforced MMCs
• Continuous fiber or sheet reinforced MMCs
Important Metallic Matrices
A variety of metals and their alloys can be used as matrix materials. We describe briefly
the important characteristics of some of the more common ones.
Important Metallic Matrices
The various metals/alloys used as matrix for metal matrix composites are given below;
1. Aluminium Matrix Composites
2. Copper Matrix Composites
3. Titanium Matrix Composites
4. Magnesium Matrix Composites
1.Aluminium Matrix Composites

Both pure aluminium and aluminium alloys can be selected as composite matrix
materials, of which the most commonly used matrix materials are aluminium alloys. Al–Cu–
Mg, Al–Zn–Mg–Cu alloys, Al–Si, Al–Mg, and Al–Cu alloys, which are commonly applied in
industry, have been used for fabrication of aluminium matrix composites. Aluminum-lithium
alloys form one of the most important precipitation-hardenable aluminum alloys. Lithium,
when added to aluminum as a primary alloying element, has the unique characteristic of
increasing the elastic modulus and decreasing the density of the alloy.
At present, aluminium matrix composite research is concentrated on two aspects:
(1) continuous fibre-reinforced aluminium
(2) discontinuously reinforced aluminium matrix composites
Continuous Fiber-Reinforced Aluminum Matrix Composites
The most commonly used long fibers are carbon fibers and boron fibers. Comparatively, boron
fiber-reinforced aluminum composites offer better all-round performance, near-perfect
compound processing because of the rich fabrication experience and more mature engineering
applications. During the fabrication process, it is necessary to overcome the interface reaction
between the Al matrix and the C fiber, because the Al matrix reacts with the C fiber to form an
Al4C3 brittle phase which can diminish the composite performance.
Continuous fiber-reinforced aluminum matrix composites with high specific strength,
high specific modulus, relatively high strength at high temperatures, good dimensional
stability, and other advantages are mainly used as structural materials in aerospace fields, such
as space shuttles, artificial satellites, and space stations. Load-carrying tube components
produced using B/Al composites are widely applied in aerospace and aircraft. Such tube
components have not only been made into the fan blades of turbofan engines but also into the
fan blades and guide blades of high-performance aeroengines.

Discontinuously Reinforced Aluminum Matrix Composites: For discontinuously reinforced

aluminum matrix composites, the reinforcements can be divided into short fibers, whiskers,
and particles. Short fibers used include C, SiC, Si3N4, Al2O3, aluminum silicate, and mullite.
Short fiber-reinforced aluminum matrix composites with high strength, high stiffness, and
excellent abrasion resistance. C fiber-reinforced aluminum matrix composites show high
specific strength, high specific stiffness, a low thermal expansion coefficient, no moisture
absorption, anti-radiation properties, high electrical conductivity, high thermal conductivity,
and good dimensional stability. In addition, they do not release gas during use. As structural
and functional materials, these composites have quite wide application prospects in the
aerospace and civilian fields. SiC fiber-reinforced aluminum matrix composites with their
lightweight, high heat resistance, high strength, and anti-fatigue properties can be used as
components in airplanes, automobiles and machinery, as well as in sports equipment.
Aluminum silicate fiber-reinforced composites exhibit excellent anti-wear properties.
Commonly used particle reinforcements include carbides (SiC, B4C, and TiC), borides (TiB2),
nitrides (Si3N4), and oxides (Al2O3), as well as C, Si, and graphite crystal particles. Among
these particles, SiC is the most commonly used reinforcement.
Copper Matrix Composites
Copper matrix composites not only have high strength, electrical conductivity, and
thermal conductivity similar to pure copper, but also have good arc erosion and abrasion
resistance. These composites are a new kind of material with wide application prospects in
high-tech electrical conduction energy-saving fields, such as aerospace, electronic, and
electrical equipment and micro-motor applications. With the continuing development in the
machinery and electronic industries, there are increasingly urgent demands for these copper
matrix composites with their high strength and high electrical conductivity. Copper matrix
composites can be classified into continuous fiber-reinforced copper composites and
discontinuous fiber-reinforced copper composites.
Continuous Fiber-Reinforced Copper Matrix Composites: Nonmetal or metal fiber-
reinforced copper or copper alloy matrix composites not only retain the high electrical
conductivity and high thermal conductivity of copper, but also exhibit high strength and high-
temperature resistance.
For example, carbon fiber-reinforced copper matrix composites combine the
advantages of carbon fibers, such as self-lubrication, wear resistance, and a low thermal
expansion coefficient, with the advantages of copper, such as good conductivity and thermal
conductivity; consequently greatly extend the material service life; and enhance its reliability.
Carbon fiber-reinforced copper matrix composites are not only used in sliding electrical contact
materials, brushes, power semiconductor support electrodes and integrated circuit radiators,
but also have a number of potential applications in the load bearings of the automobile engine,
and the powder metallurgy bearings of printing machinery, papermaking machinery, textile
machinery, and light industrial machinery.
Discontinuously Reinforced Copper Matrix Composites:
Discontinuously reinforced copper matrix composites include short carbon fiber-reinforced
copper matrix composites, particle-reinforced copper matrix composites, in situ copper matrix
composites, and other copper matrix composites.
(1) Short carbon fiber-reinforced copper matrix composites
In short fiber-reinforced metal matrix composite fabrication, the important points are
avoiding mechanical damage to the fibers when adding them to the matrix, completely
dispersing the fibers into the matrix, and obtaining perfect bonding between fiber and matrix.
Powder metallurgy methods are often used to manufacture discontinuous carbon fiber-
reinforced copper matrix composites. This is mainly because the powder metallurgy method
with its single forming process can avoid subsequent machining and save raw materials
The fibers used to reinforce copper alloys include carbon fibers, tungsten wires,
graphite fibers, alumina fibers, carbon nanotubes, silicon carbide fibers, and steel fibers.
Among these fibers, tungsten wires and carbon fibers are the most commonly used
reinforcements.
(2) Particle-reinforced copper matrix composites
The preparation methods for particle-reinforced copper matrix composites are similar
to those of other particle-reinforced metal matrix composites and include conventional casting,
conventional powder metallurgy, the co-deposition method, and the internal oxidation method.
Tungsten, molybdenum, tungsten carbide, and alumina are usually used as reinforcements
because of their high-temperature hardness, high melting points, and anti-adhesion properties.
Using the powder metallurgy method, the reinforcements and Cu powders are mixed and are
then sintered together to form copper matrix composites.
(3) In situ reinforced copper matrix composites
In situ reinforced copper matrix composites are fabricated by the following method. By
forging, drawing, or rolling a series of Cu–X alloys, the X metals form filamentous or zonal
distributions along the deformation direction, and consequently form Cu–X microstructure
composites. During the drawing and rolling process, the X elements are elongated under the
axial force into filamentous or zonal distributions with thicknesses of less than 10 nm. The
contribution of the filamentous body to the overall strength of the microstructural composites
is not large, because thinning of the filamentous body can increase the phase interface and
hamper dislocation movement.
Titanium Matrix Composites
Titanium matrix composites (TMCs), with their high specific strength, high specific
stiffness, and good high-temperature resistance, are widely used in the aerospace. TMCs can
be divided according to their reinforcement types into two categories: continuous fiber-
reinforced titanium matrix composites and discontinuous particle or whisker-reinforced
titanium matrix composites.
Continuous Particle-Reinforced Titanium Matrix Composites
 The continuous fiber reinforcements used are mainly ceramic fibers such as alumina,
boron carbide, and silicon carbide, and they exhibit high melting points, good thermal stability,
high specific strengths, and high specific stiffnesses. Among these ceramic fibers, both alumina
and boron fibers have thermal expansion coefficients that are very close to that of the titanium
matrix, but boron fibers cannot resist high temperatures and alumina fibers react very strongly
with the titanium matrix, so their applications are significantly restricted. At present, carbon-
coated SiC fibers are commonly used in industry. Continuous SiC fiber-reinforced TMCs offer
high specific strength, high specific stiffness, high service temperatures, and good fatigue and
creep properties. These composites also exhibit extremely high thermal stability, and their
mechanical properties are not reduced after heat exposure at 700 °C for 2000 h.
Discontinuous Particle-Reinforced Titanium Matrix Composites
Reinforcements for particle-reinforced titanium matrix composites (PTMCs) include
carbides such as TiC, B4C, and SiC; borides such as TiB and TiB2; metal oxides such as Al2O3,
Zr2 O3, and R2O3 (where R is a rare earth element); and intermetallic compounds such as
Ti3A1, TiAl, and Ti5Si3. Among these particles, the most commonly used reinforcements are
TiB, TiB2, and TiC.
Magnesium Matrix Composites
Magnesium and its alloys form another group of very light materials. Magnesium is
one of the lightest metals; its density is 1.74 g/cm3. Magnesium alloys, especially castings, are
used in aircraft gearbox housings, chain saw housings, electronic equipment, etc.Magnesium,
being a hexagonal close-packed metal, is difficult to cold work. Magnesium has high specific
strength, high specific stiffness, good damping properties, and excellent processing
performance.
Magnesium matrix composites can be divided according to their reinforcement types
into three categories: continuously reinforced magnesium matrix composites, discontinuously
reinforced magnesium matrix composites, and in situ reactive self-reinforced magnesium
matrix composites.
Continuous Fiber-Reinforced Magnesium Matrix Composites
The main continuous reinforcements for magnesium matrix composites can be divided
into two categories: Al2O3 fibers and carbon (graphite) fibers. Carbon (graphite) fiber-
reinforced magnesium matrix composites are the most widely investigated type. Carbon
(graphite) fiber-reinforced magnesium matrix composites have been prepared in Japan, and
their strength and elastic modulus values have reached 1200 MPa and 570 GPa, respectively.
Continuous fiber-reinforced magnesium matrix composites have very broad application
prospects in the aerospace and automotive fields. NASA has used graphite (Gr)/Mg composites
to fabricate
Components including space power recovery system components, space station struts,
and space mirror holders. However, their development is limited by the high cost of the long
fibers and the difficulties of composite preparation.

Discontinuously Reinforced Magnesium Matrix Composites

 Discontinuously reinforced magnesium matrix composites exhibit not only high
strength, high modulus, high hardness, excellent wear resistance, and good damping properties,
but also excellent machinability, good dimensional stability, and isotropic properties, which are
advantageous for structure design.
Discontinuously reinforced magnesium matrix composites exhibit low density, high wear
resistance, high specific stiffness, excellent dimensional stability, and high-temperature
performance. Therefore, they can be used to produce not only aerospace components such as
satellite antennas and helicopters, but also car parts, I ncluding discoid impellers, piston ring
grooves, gears, transmission bearings, differential bearings, forks, connecting rods, and
rockers.

Production techniques of Metal Matrix Composites

Processing of metal matrix composites (MMC) can be classified into three main categories:
1. Solid State Processing
a) Powder Metallurgy
b) Diffusion Bonding
2. Liquid State Processing
 a) Stir Casting:
b) Squeeze Casting
c) Infiltration Process:
3. In-Situ Processing

1.Powder Metallurgy

powder metallurgy includes uniform mixing of reinforcement with metal alloy and blending of
powders; then cold pressing of powder, degassing the solidified product in vacuum and then
hot pressing and finally extrusion

Initialyy the

metal matrix powder ( in particulate form) for eg.Al and reinforcement mixed together and
blended. The blended mixture is then subjected to cod pressing. Cold isostatic pressing is used
for this purpose.In this the mixture is pressed by equal pressure from all sides.The cold pressed
solid is then subjected to vacuum degassing.Vacuum degassing is a process of romoving any
gas from the cold pressed mixture. After vacuum degassing the semi solid mixture is hot
pressed in a die at high temperature. Then sufficient bonding between particles takes place.
Then the solid element id extruded into the final shape.
2.Diffusion Bonding

Diffusion bonding is a common solid state welding technique used to join similar or
dissimilar metals. Interdiffusion of atoms from clean metal surfaces in contact at an elevated
temperature leads to welding. Matrix alloy foil and fiber arrays, composite wire, or monolayer
laminae are stacked in a predetermined order a shown in fig. Figure shows a schematic of one
such diffusion bonding process, also called the foil-fiber-foil process. The fibres placed in
between metal foil (aluminium) and then it is cut into shape.Successive layers added. Now air
and other gases are removed from the voids of the layrs.Then heat is applid and the part is
pressed to get the consolidated composite.Finalyy the composite is cut into the shape

Stir Casting

It is a liquid state method of composite materials fabrication, in which a dispersed phase

(ceramic particles, short fibers) is mixed with a molten matrix metal by means of mechanical
stirring. Stir casting as shown in fig. is the simplest and the most cost effective method of
liquid state fabrication. The liquid composite material is then cast by conventional casting
methods and may also be processed by conventional Metal forming technologies.
Here the reinforcements in the form of powder is supplied through a chute into a
graphite crucible which contains the molten metal matrix. The molten metal matrix and the
reinforcemenr powder is stirred in the crucible by means of a DC motor. After stirring process
the liquid composite material is then cast by conventional casting methods and may also be
processed by conventional Metal forming technologies
Infiltration process

1.Squeeze Casting or pressure infiltration

Squeeze casting or pressure infiltration involves forcing a liquid metal into a fibrous or
particulate Preform (Fig.4). In this technique the molten metal is forced-infiltrated into fibre
bundles or preformed, expelling all absorbed and trapped gasses This method involves placing
a preheated preform of reinforcement into a preheated die, filling the die with molten matrix
metal, squeezing the molten metal into the preform using a hydraulic press with a preheated
ram, holding the pressure during solidification, releasing the pressure and ejecting the resulting
composite The preheated reinforcement, usually in the form of a pre-compacted and
inorganically bonded preform, is placed in a preheated metal die Superheated liquid metal is
introduced into the die and pressure is applied to drive the metal into the interstices between
the reinforcing materials The pressure required to combine matrix and the reinforcement is a
function of the friction effects due to viscosity of the molten matrix as it fills the ceramic
preform Squeeze casting produces components, which are free from gas or shrinkage porosity
2. Gas pressure Infiltration Process
In the squeeze casting process high pressure is applied through a ram to infiltrate the liquid
metal into the porous preformed reinforcement. But in gas infiltration process using a
pressurized gas for applying pressure on the molten metal and forcing it to penetrate into a
preformed dispersed phase as shown in fig. Gas Pressure Infiltration method is used for
manufacturing large composite parts.

In Situ Process
In situ fabrication of Metal Matrix Composite is a process, in which dispersed
(reinforcing) phase is formed in the matrix as a result of precipitation from the melt during its
cooling and Solidification.
Different types of Metal Matrix Composites may be prepared by in situ fabrication method:
1. Particulate in situ MMC – Particulate composite reinforced by in situ synthesized dispersed
phase in form of particles.
Examples: Aluminum matrix reinforced by titanium boride (TiB2) particles, magnesium
matrix reinforced by Mg2Si particles.
2. Short-fiber reinforced in situ MMC – Short-fiber composite reinforced by in situ
synthesized dispersed phase in form of short fibers or whiskers (single crystals grown in form
of short fibers).
Examples: Titanium matrix reinforced by titanium boride (TiB2) whiskers,
Aluminum matrix reinforced by titanium aluminide (TiAl3) whiskers.
3. Long-fiber reinforced in situ MMC – Long-fiber composite reinforced by in situ
synthesized dispersed phase in form of continuous fibers.
Example: Nickel-aluminum (NiAl) matrix reinforced by long continuous fibers of Mo (NiAl-
9Mo alloy).
Dispersed phases of in situ fabricated Metal Matrix Composites may consist of intermetallic
compounds, carbides, borides, oxides, one of eutectic ingredients.
Unidirectional solidification of a eutectic alloy (alloy of eutectic composition) may result in
formation of eutectic structure, in which one of the components has a form of long continuous
filaments.
Scheme of a device for unidirectional solidification of in situ Metal Matrix Composite is shown
in the figure:

Crucible with an eutectic alloy moves downwards (or alternatively the induction coil moves
upwards). This movement results in remelting followed by re solidification of the alloy under
controlled cooling conditions.
Value of heat transfer through the crucible bottom together with the crucible speed (v) and the
power of the heating elements (induction coil) determine particular temperature gradient,
which provides unidirectional solidification with flat solidification front.

The alloy acquires eutectic structure directed along the solidification direction with eutectic
components in form of long mono-crystals (fibers).
Advantages of in situ Metal Matrix Composites:
▪ In situ synthesized particles and fibers are smaller than those in materials with separate
fabrication of dispersed phase (ex-situ MMCs). Fine particles provide better
strengthening effect;
▪ In situ fabrication provides more homogeneous distribution of the dispersed phase
particles;
▪ Bonding (adhesion) between the particles of in situ formed dispersed phase and the
matrix is better than in ex-situ MMCs;
▪ Equipment and technologies for in situ fabrication of MMCs are less expensive.
Disadvantages of in situ Metal Matrix Composites:
▪ Choice of the dispersed phases is limited by thermodynamic ability of their
precipitation in particular matrix;
▪ The size of dispersed phase particles is determined by solidification conditions;