ASSIGNMENT No.

2
APPLIED CHEMISTRY-I (Theory)
_____________________________________________________________________

Submission Date(April 20, 2019)

BY
Group-II
Anum Allah Bakhsh (18120807-004)
Rabiya Nafees (18120807-027)
Komal Shahzadi (18120807-055)
Hajra Iftikhar (18120807-013)
Romeena Ayoob (18120807-028)
Saira Toor (18120807-050)
Aqsa Mubeen (18120807-053)
Aimen Aslam (18120807-042)

CHEM-347

MSc-II CHEMISTRY
TO
Dr. Muhammad Zubair
Department of Chemistry
Semester Spring 2019

_____________________________________________________________________

UNIVERSITY OF GUJRAT

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 Table of CONTENTS

1. Composite Materials………………………………..………………………………………..3
1.1. Classification ………………………….…………………………………………..………3
2. Metal-Matrix Composites……..……,,,……………….…………………………………… 4
2.1. Important metal matrices…...…………………………………………………….……… 4
3. Classificationof MMCs ………………..……………………………………………………5
4. Composition…………………………..…………………………..…………………………6
5. Matrix ……………………………………………………………….………………………6
6. Reinforcement……………………………………………………………………………… 7
7. Manufacturing and forming methods………...…………………………...…..….…..……8
7.1. Solid state methods……………………………………………………….……………….8
7.2. Liquid state methods…………………………………………………….……………….11
7.3. In-situ fabrication technique………………………………………………….………….13
7.4. Decomposition technique……………………………………………………..…………15
8. Applications of MMCs………………………………..…………………..…….…………19
9. Advantages of MMCs………..………………………………….…………….………...…21
10. Disadvantages …………………………………………………………...…………………21
11. Conclusion……………………………………………….…………………………………22

12.References………………………………………………………..…………………………..23

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 METAL MATRIX COMPOSITES

1. Introduction of Composite Materials

Composites consist of two or more physically and or chemically distinct materials. There are
three components of a composite:

 Matrix

 Reinforcement

 Filler between matrix and reinforcement.

A matrix is a continuous phase of composites and serves to hold the reinforcements in

predetermined orientation. A reinforcement is a stronger material distributed within the matrix.
Matrix and reinforcements are chemically bonded or mechanically locked together. Matrix,
reinforcements, and the interface determine the characteristics of a composite. While the
characteristics of a matrix material are changed in the composite making process, those of
reinforcing materials remain the same except in rare instances of processing at very high
temperature.

1.1. Classification of Composites

Composites are classified based on the types of matrix and reinforcements. Composites are
classified as:

 Polymer matrix composites (PMCs)

 Metal matrix composites (MMCs)

 Ceramics matrix composites (CMCs)

Depending on the types of reinforcements, composites include particle reinforced composites, short
fiber composites (whisker), and continuous fiber composites (sheet). The materials for reinforcements

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can be organic fibers, metallic fibers, ceramic fibers, and particles. The materials for matrices can be
polymers, metal and its alloys, glasses, glass-ceramics, ceramics. Usually, the strength of a matrix is
considerably less than that of a fiber reinforcement.

2. Metal Matrix Composites

A metal matrix composite (MMC) is composite of material with at least two constituent parts,
one being a metal necessarily (matrix), the other material may be a different metal or another
material (reinforcement), such as a ceramic or organic compound. The volume fraction of the
reinforcement is typically in the range 10-70%. MMCs can offer a range of property
enhancement over monolithic alloys. A large variety of metal-matrix composite exist. The
reinforcing phase can be fibrous, plate-like, or equi-axed ( having equal dimensions in all
directions. They can also be vary according to their size.

2.1. Important Metal Matrices

Numerous metals have been used as matrices. The most important have been aluminum,
titanium, magnesium, and copper alloys and super alloys.

The most important MMC systems are:

 Aluminum matrix
 Continuous fibers: boron, silicon carbide, alumina, graphite
 Discontinuous fibers: alumina, alumina-silica
 Whiskers: silicon carbide
 Particulates: silicon carbide, boron carbide
 Magnesium matrix
 Continuous fibers: graphite, alumina
 Whiskers: silicon carbide
 Particulates: silicon carbide, boron carbide
 Titanium matrix
 Continuous fibers: silicon carbide, coated boron

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  Particulates: titanium carbide
 Copper matrix
 Continuous fibers: graphite, silicon carbide
 Wires: niobium-titanium, niobium-tin
 Particulates: silicon carbide, boron carbide, titanium carbide.
 Superalloy matrices
 Wires: tungsten
3. Classification of MMC

MMC are classified into four major types given as

Fig 1: Classification of MMCs

3.1.1. Dispersion Hardened and particles:

Particulate reinforced MMC containing either particle or platelets that range in size from 0.05 to
100 Um. The particulates can be incorporated into the metal matrix to higher volume fraction
than the whiskers.

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3.1.2. Layer composites or Laminates:

Laminates are composites in which layers of different materials are bonded together with
adhesive, to give added strength, durability, or some other benefit. Laminates tend to be based on
four main materials: wood, glass, fabric, and paper. It's also important to remember that a
laminate isn't simply several layers of materials: the materials have to be permanently bonded
together with something like adhesive, so they behave as one material, not several.

3.1.3. Fiber composites:

Fiber reinforced MMC containing either continuous or discontinuous fiber reinforcements, the
latte being in the form of whiskers that are approximately 0.1-0.5 𝜇m in diameter and have a
length to diameter ratio upto 200.

3.1.4. Infiltraion Composites:

Infiltration is a liquid state method of composite materials fabrication, in which a preformed

dispersed phase (ceramic particles, fibers, woven) is soaked in a molten matrix metal, which fills
the space between the dispersed phase inclusions. Infiltration is one of the methods of
preparation of tungsten-copper composites.

4. Composition:

Matel Matrix Composites are made by dispersing a reinforcing material into a metal matrix. The
reinforcement surface can be coated to prevent a chemical reaction with the matrix. For
example, carbon fibers are commonly used in aluminium matrix to synthesize composites
showing low density and high strength. However, carbon reacts with aluminium to generate a
brittle and water-soluble compound Al4C3 on the surface of the fiber. To prevent this reaction,
the carbon fibers are coated with nickel or titanium boride.

5. Matrix:

The matrix is the monolithic material into which the reinforcement is embedded, and is
completely continuous. This means that there is a path through the matrix to any point in the
material, unlike two materials sandwiched together. In structural applications, the matrix is
usually a lighter metal such as aluminum, magnesium, or titanium, and provides a compliant

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 support for the reinforcement. In high-temperature applications, cobalt and cobalt–nickel alloy
matrices are common.

6. Reinforcement:

The reinforcement material is embedded into a matrix. The reinforcement does not always serve
a purely structural task (reinforcing the compound), but is also used to change physical
properties such as wear resistance, friction coefficient, or thermal conductivity. The
reinforcement can be either continuous, or discontinuous. Discontinuous MMCs can be isotropic,
and can be worked with standard metalworking techniques, such as extrusion, forging, or rolling.
In addition, they may be machined using conventional techniques, but commonly would need the
use of polycrystalline diamond tooling (PCD).

Continuous reinforcement uses monofilament wires or fibers such as carbon fiber or silicon
carbide. Because the fibers are embedded into the matrix in a certain direction, the result is
an anisotropic structure in which the alignment of the material affects its strength. One of the
first MMCs used boron filament as reinforcement.

Discontinuous reinforcement uses "whiskers", short fibers, or particles. The most common
reinforcing materials in this category are alumina and silicon carbide.

Reinforcements for metal matrix composites have a manifold demand profile, which is
determined by production and processing and by the matrix system of the composite material.

For metal reinforcement ceramic particles or, rather, fibers or carbon fibers are often used. Due
to the high density and the affinity to reaction with the matrix alloy the use of metallic fiber usual
fails.

The wide variety of MMCs have properties that differ dramatically. Factors influencing their
characteristics include:

 Reinforcement properties, form, and geometric arrangement

 Reinforcement volume fraction

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 Matrix properties, including effects of porosity
 Reinforcement-matrix interface properties
 Residual stresses arising from the thermal and mechanical history of the composite
 Possible degradation of the reinforcement resulting from chemical reactions at high
temperatures, and mechanical damage from processing, impact, etc.

7. Manufacturing and Forming Methods:

Processing of metal matrix composites (MMC) can be classified into three main categories:

a) Solid State Processing

b) Liquid State Processing
c) In-Situ Processing
d) -Deposition Technique

Fig 2: Method Processing of MMCs

7.1. Solid state methods

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Solid state fabrication of Metal Matrix Composites is the process, in which Metal Matrix
Composites are formed as a result of bonding matrix metal and dispersed phase due to mutual
diffusion occurring between them in solid states at elevated temperature and under pressure. The
main fabrication methods for solid state processing of metal matrix composites are powder
blending and consolidation, and physical vapor deposition.

7.1.1. Sinter-Forging:

Sintering fabrication of Metal Matrix Composites is a process, in which a powder of a matrix

metal is mixed with a powder of dispersed phase in form of particles or short fibers for
subsequent compacting and sintering in solid state (sometimes with some presence of liquid).
Sintering is the method involving consolidation of powder grains by heating the “green”
compact part to a high temperature below the melting point, when the material of the separate
particles diffuse to the neighboring powder particles.

Fig 3: Sintering Process

Metal alloy powder is blended with ceramic whisker/short fiber/particles in dry condition or in
liquid suspension. After blending, the mixture is further processed by cold compaction, canning,
degassing, and high temperature consolidation. There are some oxide particles in volume fraction
of 0.05-0.5 depending on the powder and processing conditions that help dispersion-
strengthening of the metal matrix composites. This method is usually used for the processing of
aluminum and magnesium metal matrix composites.

7.1.2. Diffusion Bonding:

Diffusion Bonding is a solid state fabrication method, in which a matrix in form of foils and a
dispersed phase in form of long fibers are stacked in a particular order and then pressed at

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elevated temperature .The finished laminate composite material has a multilayer structure. The
inter diffusion atoms at the metallic surfaces under pressure creates bonding between the metal
matrix and fibers. This fabrication method is widely used for aluminum or magnesium MMCs
reinforced with continuous/discontinuous fibers.

Fig 4 Diffusion Bonding processing

7.1.3. Powder Processing:

Metal alloy powder is blended with ceramic whisker/short fiber/particles in dry condition or in
liquid suspension. After blending, the mixture is further processed by cold compaction, canning,
degassing, and high temperature consolidation. There are some oxide particles in volume fraction
of 0.05-0.5 depending on the powder and processing conditions that help dispersion-
strengthening of the metal matrix composites. This method is usually used for the processing of
aluminum and magnesium metal matrix composites.

Fig 5: Powder Processing

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7.1.4. Deformation:

By far the most widely used method for producing particulate reinforced MMCs by powder
metallurgy processing is to combine the matrix and reinforcement powders together in the form
of an intermediate billet which is then utilized for subsequent deformation processing to final
product form.

Fig 6: Deformation Process

This type of processing involves first combining the metallic matrix powder and reinforcement
through a blending process, followed by (in the case of aluminum alloys) steps for degassing and
modification of the aluminum oxide film present on the aluminum powders, as discussed
elsewhere in this volume. To form the final consolidated billet, a variety of processes such as
vacuum hot pressing, hot isostatic pressing, and liquid-phase sintering are employed.

7.2. Liquid state method

Liquid state fabrication of Metal Matrix Composites involves incorporation of dispersed phase
into a molten matrix metal, followed by its Solidification. In order to provide high level of
mechanical properties of the composite, good interfacial bonding (wetting) between the
dispersed phase and the liquid matrix should be obtained.

The methods of liquid state fabrication of Metal Matrix Composites:

7.2.1. Stir Casting or Liquid Infiltration:

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Stir Casting 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 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.

Stir Casting is characterized by the following features:

 Content of dispersed phase is limited (usually not more than 30 vol. %).
 Distribution of dispersed phase throughout the matrix is not perfectly homogeneous:
A) There are local clouds (clusters) of the dispersed particles (fibers);

B) There may be gravity segregation of the dispersed phase due to a difference in the
densities of the dispersed and matrix phase.
 The technology is relatively simple and low cost.

Distribution of dispersed phase may be improved if the matrix is in semi-solid condition.

The method using stirring metal composite materials in semi-solid state is called Rheocasting.

High viscosity of the semi-solid matrix material enables better mixing of the dispersed phase.

An example of this method is Al-(10-15%) B4C MMCs.

7.2.2. Squeeze Casting or Pressure Infiltration

Squeeze Casting Infiltration is a forced infiltration method of liquid phase fabrication of Metal
Matrix Composites, using a movable mold part (ram) for applying pressure on the molten metal
and forcing it to penetrate into a performed dispersed phase, placed into the lower fixed mold
part. Squeeze Casting Infiltration method is similar to the Squeeze casting technique used for
metal alloys casting.

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 Fig 7: Squeeze Casting Infiltration

Squeeze Casting Infiltration process has the following steps:

 A preform of dispersed phase (particles, fibers) is placed into the lower fixed mold half.
 A molten metal in a predetermined amount is poured into the lower mold half.
 The upper movable mold half (ram) moves downwards and forces the liquid metal to
infiltrate the preform.
 The infiltrated material solidifies under the pressure.
 The part is removed from the mold by means of the ejector pin.
 The method is used for manufacturing simple small parts (automotive engine pistons
from aluminum alloy reinforced by alumina short fibers).

7.3. In-situ fabrication technique

In situ fabrication of Metal Matrix Composite is a process, in which dispersed 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:

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 1. Particulate in situ MMC: Particulate composite reinforced by in situ synthesized
dispersed phase in form of particles. Example are 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). Example are Titanium matrix reinforced by titanium boride (TiB2)
whiskers and Aluminum matrix reinforced by titanium aluminide (TiAl3) whiskers.
3. Long-fiber reinforced in situ MMCs: Long-fiber composite reinforced by in situ
synthesized dispersed phase in form of continuous fibers. Examples are Nickel-aluminum
(Ni-Al) matrix reinforced by long continuous fibers of Mo (NiAl-9Mo alloy).

Scheme of a device for unidirectional solidification of in situ Metal Matrix Composite is:

Fig 8: In-situ fabrication procedure

Crucible with an eutectic alloy moves downwards (or alternatively the induction coil moves
upwards). This movement results in remelting followed by resolidification of the alloy under
controlled cooling conditions. Value of heat transfer through the crucible bottom together with

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the crucible speed and the power of the heating elements (induction coil) determine particular
temperature gradient, which provides unidirectional solidification with flat solidification front.

7.4. Deposition Technique:

Fibers are continuously passed through a region of high partial pressure of metal to be deposited.
The vapor is produced and inserted in the process, then the condensation occurs at this region to
produce a coating on the fiber. The rate of deposition is about 5-10 micrometer per minute. The
coated fibers are then consolidated by hot pressing or hot isostatic pressing .

Fig 9: Vapor deposition

 Spray Deposition

Particle/whisker/short fiber reinforcements are injected into the spray, creating a deposition layer
of porosity of 5-10% on the metal surface. The depositions are then consolidated to full density
by further processing.

For continuous (long) fiber reinforced metal matrix composites, matrix metals are sprayed onto
the fibers. The fiber spacing and fiber layer in this processing method impact the fiber volume
fraction and distribution.

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 Fig 10: Spray Deposition

8. Microstructure of MMCs:

The damping behavior of unidirectional fiber-reinforced metal-matrix composites (MMCs), such

as boron/aluminum, graphite/aluminum, and graphite/magnesium is reviewed to examine the
effect of microstructure on material damping. This shows that microstructural features do play an
important role in composite material.

Figure 1: showing microstructure

Various forms of microstructure of MMCs

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 Figure :2

Study of microstructure of Cu-SiC (metal metrix composite):

In the present investigation, pure Cu sheets were reinforced with 25 μm SiC particles to fabricate
a composite surface layer by friction stir processing (FSP). In order to improve distribution of
reinforcing SiC particles, a net of holes were designed by drill on the surface of pure Cu sheet.
For evaluation of microstructure, Optical Microscope (OM) and Scanning Electron Microscope
(SEM) were used. Microstructural observation confirmed fine and equiaxed grains in the stir
zone (SZ) and showed that SiC particles act as heterogeneous nucleation sites in the dynamic
recrystallization of Cu grains. Moreover, agglomeration of particles was not observed and fine
particles had a good distribution in SZ. In the SEM micrographs, porosities were detected as
microstructure defects. Microhardness measurements showed that surface hardness was two
times as high as that of substrate.

The matrix microstructure was systematically varied by heat treating to either an under- or over-
aged condition of equivalent strength, and was characterized using a combination of techniques.
Quantitative metallographic techniques were utilized to characterize the material with respect to
size, size distribution, and particle clustering, while transmission electron microscopy was
utilized to characterize the details of the matrix microstructure in addition to the effects of aging

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on the character of the particle/matrix interfaces. Large effects of microstructure on the notched
properties were obtained with little effect of microstructure on tensile ductility. It is shown that
the micromechanisms of fracture are significantly affected by the details of the matrix
microstructure, interface character, and degree of clustering in the material. Fracture of the SiC
was predominant in the underaged materials, with a preference for failure in the matrix and near
the interface in the overaged material. Metallographic and fractographic analyses revealed that
clustered regions were preferred sites for damage initiation in both the aging conditions tested,
while preliminary results additionally indicate that damage accumulation ahead of a propagating
crack also tended to occur in clustered regions.

Effect of microstructure:

The main challenge in the development and processing of composite materials is to control the
microstructure, mechanical properties, and cost of the product. The aluminum metal matrix
composite materials are the combination of two or more constituents in which one is matrix and
other is reinforcement. If the casting processes of the melted metal are applied directly in the
state of melted Al matrix with reinforcement, the reinforced metal matrix composite parts with
the complicated shape can be produced. However, it is hard to get the products for the
reinforcement to be distributed uniformly because of the difference of densities of matrix and
reinforcement in metal matrix composite.

. Several techniques have been employed to prepare the composites including powder
metallurgy, melt techniques etc. Investigation of mechanical behavior of aluminum alloys
reinforced by hard particles such as SiC is an interesting area of research. Therefore, the aim of
the work is to investigate the effects of different factors such as: (i) weight percentage of the SiC
particles (ii) type of fabrication process (mechanical stir and electromagnetic stir casting) on the
microstructure, of the metal matrix composites .On the basis this work, the compositions of
reinforcement selected in a multiplication of 5 and the percentage of reinforcements are varied
from 0 to 15% weight fraction in metal matrix. If the weight percentage of reinforcement’s
increases more than 15% there is no more effect occurring in physical and chemical properties of
metal matrix composite. This work aims to compare the result of aluminum matrix composite

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material reinforced by (0, 5, 10, and 15 wt.%) silicon carbide particles using electromagnetic stir
casting method and mechanical stir casting method.

9. Applications of metal matrix composites

1) In Tungsten carbide cutting tools

High performance tungsten carbide cutting tools are made from a tough cobalt matrix cementing
the hard tungsten carbide particles; lower performance tools can use other metals such as bronze
(an alloy consisting primarily of copper, commonly with about 12–12.5% tin) as the matrix.

2) In tank armors

Some tank armors may be made from metal matrix composites, probably steel reinforced
with boron nitride, which is a good reinforcement for steel because it is very stiff and it does not
dissolve in molten steel.
3) In automotive disc brakes

Some automotive disc brakes use MMCs. Modern high-performance sport cars, such as those
built by Porsche, use rotors made of carbon fiber within a silicon carbide matrix because of its
high specific heat and thermal conductivity. 3M developed a preformed aluminum matrix insert
for strengthening cast aluminum disc brake calipers, reducing weight by half compared to cast
iron while retaining similar stiffness. 3M has also used alumina preforms for AMC pushrods

4) In drive shaft

Ford offers a Metal Matrix Composite (MMC) driveshaft upgrade. The MMC driveshaft(a
mechanical component for transmitting torque and rotation, usually used to connect other
components of a drive train ) is made of an aluminum matrix reinforced with boron carbide,
allowing the critical speed of the driveshaft to be raised by reducing inertia. The MMC driveshaft

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has become a common modification for racers, allowing the top speed to be increased far beyond
the safe operating speeds of a standard aluminum driveshaft.
5) In engines of motor cycles

Honda has used aluminum metal matrix composite cylinder liners in some of their engines.
Toyota has since used metal matrix composites in engine which is used in the later Lotus.
6) In landing gear of jet

The F-16 Fighting Falcon (a single-engine supersonic multirole fighter aircraft) uses
monofilament silicon carbide fibers in a titanium matrix for a structural component of the
jet's landing gear.
7) In bicycle frames

Specialized Bicycles has used aluminum MMC compounds for its top of the
range bicycle frames for several years. Griffen Bicycles also made boron carbide-aluminum
MMC bike frames.
8) In Particle accelerators

Some equipment in particle accelerators such as Radio Frequency Quadrupoles (RFQs) or

electron targets use copper MMC compounds retain the material properties of copper at high
temperatures and radiation levels.

9) In multi module chips

Copper-silver alloy matrix containing 55% by volume diamond particles, known as Dymalloy, is
used as a substrate for high-power, high-density multi-chip modules in electronics for its very
high thermal conductivity.
10) In power electronic modules

Aluminum-Graphite composites are used in power electronic modules because of their

high thermal conductivity, the adjustable coefficient of thermal expansion and the low density.
MMCs are nearly always more expensive than the more conventional materials they are
replacing. As a result, they are found where improved properties and performance can justify the
added cost.

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 Today these applications are found most often in:

 aircraft components,
 space systems
 high-end or "boutique" sports equipment.

The scope of applications will certainly increase as manufacturing costs are reduced.

10. Advantages of MMC:

The metal based matrix composites have numerous advantages. Some of them are given as

 Higher specific strength and modulus over metals.

 Lower coefficients of thermal expansion than metals by reinforcing with graphite.
 Tight tolerance, repeatable moldings
 Corrosion Resistance
 Design Flexibility
 Durable
 High performance at elevated temperatures
 Mechanical property retention
 Lighter weight than metal
 Low petrochemical content
 Outstanding electrical insulation
 No moisture absorption
 Better radiation resistance
 High young’s modulus
 Good process ability
11. Disadvantages of MMC:

MMCs system also have some disadvantages given below

 Higher cost of some material systems

 Relatively immature technology
 Complex fabrication methods for fiber-reinforced systems(except for casting)

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  Less well known process
 Less stronger parts than wrought ones
 Machining difficult
 Fiber-matrix interactions at high temperature degrade fibers
 Reinforcement material may reduce ductility and fracture toughness

Conclusion:

Over the period MMCs proved their importance and are contributing the progress and
evolution of mankind.

The MMCs have satisfied the designer conceptions, in such a way that act as functional
materials for advanced applications. These composites can solve the major problems
associated with many applications only if these are designed to achieve the standards.

The high cost of MMC is attributed to the cost of reinforced materials and matrix metals and
the processing expenses. At present, several vapor deposition processes are being employed
in the fraction of MMCs, but still the cost factor is keeping them away day to day
applications. Novel, cost effective methods have to be accomplished in order to achieve the
market for MMCs.

Metal matrix composites offer sufficient promise and have reached the degree of maturity
that indicates an expansion of their use. To realize their full potential however these
composites deserve greater attention and support.

The number of MMCs currently are in various stages of development:

These are boron/aluminium, beryllium/titanium, and boron/titanium, graphite/aluminium and

super alloys reinforced with refractory metal.

The boron/reinforced aluminium system is in most advanced stage of development and

properly data for this system are sufficient for design in structural application.

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References

 https://www.sciencedirect.com/topics/materials-science/metal-matrix-composite

 https://onlinelibrary.wiley.com/doi/abs/10.../0471238961.1305200103080123.a01.pub3

 https://www.sciencedirect.com/topics/materials-science/metal-matrix-composite

 https://www.tms.org/pubs/journals/jom/0104/rawal-0104.html

 https://en.wikipedia.org/wiki/Metal_matrix_composite

 https://www.elsevier.com/books/metal-matrix-composites/taya/978-0-08-036984-6

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