Composite Materials:

The word composite in composite materials means that two or more materials are combined together in a
certain order on a macroscopic level to form a new material with different and attractive properties. The
reason alloys are not considered in this category is because they are homogeneous on the macroscopic level.
A composite material consists of two phases:
Primary Phase:
• Forms the matrix within which the secondary phase is imbedded. Any of three basic material types:
polymers, metals, or ceramics.
Secondary Phase:
• Referred to as the imbedded phase or called the reinforcing agent.
• Serves to strengthen the composite. (fibers, particles, etc.).
Composite materials consist of a bulk material called the matrix, and a filler of some types such as fibers,
whiskers or particles

Properties of a composite:
The properties of a composite material depend on the following:
 Properties of constituent phases.  Shape of particles.
 Relative amounts of constituents.  Particle size.
 Geometry of the dispersed phase.  Particle distribution.
 Interfacial reactions between constituents phases

Rule of Mixture (ROM)

Several properties of the composites may be assessed by the rule of mixture (ROM) which states that the
property of the composite is the sum of products of the property of an individual constituent and its volume
fraction in the composite. For example:
Density: Dc = Dr Vr + Dm Vm
Where, D stands for density and subscripts c, r and m stand for composite, reinforcement and matrix
respectively. This theoretical calculation can be used to check whether the composite produced has the
optimum properties. Modulus strength, Electrical properties may sometimes be estimated with ROM as the
first approximation.

Metal Matrix Composites (MMCs)

Metal matrix composites (MMCs) have been around for a long time, but have only been recognized as
legitimate engineering composite materials since the second half of the twentieth century.
Metal matrix composites (MMCs), like all composites; consist of at least two chemically and physically distinct
phases, suitably distributed to provide properties not obtainable with either of the individual phases.
Generally, there are two phases, primary and Secondary phases e.g. a fibrous or particulate phase (Secondary
phase), distributed in a metallic matrix.
Examples include
 Continuous A12O3 fiber reinforced Al matrix composites used in power transmission lines
 Nb-Ti filaments in a copper matrix for super conducting magnets
 Tungsten carbide (WC)/cobalt (Co) particulate composites used as cutting tool and oil drilling
Sic particle reinforced A1 matrix composites used in aerospace, automotive, and thermal management
applications
Processing of metal matrix composites
Processing of metal matrix composites (MMC) can be classified into three main categories:
 Solid State Processing  Liquid State Processing  In-Situ Processing
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Fabrication of metal matrix composites (MMCS)

Solid State Processing

The main fabrication methods for solid state processing of metal matrix composites are powder blending and
consolidation, and physical vapor deposition.
Powder Blending and Consolidation:
Metal alloy powder is blended with ceramic whisker/short fiber/particles in dry condition or in

of 0.05-0.5 depending on the powder and processing conditions that help dispersion- through a
strengthening of the metal matrix composites.

Shaping of metal
by heating in fire
and hammering
happen in the dry
of dispersion agents
atmospheres or by
(MA). Fig. show
operational sequence of
production

b) Diffusion Bonding:
This method is usually used for the processing of aluminum and
magnesium metal matrix composites. This method in cross-sec

and/or
mechanical
schematically
compress
liquid suspension. After blending, the mixture is further processed by cold compaction, canning, which th
degassing, and high temperature consolidation. There are some oxide particles in volume fraction is

to produ

manufacture of MMC is by first mixing the existing powders of matrix metal

and reinforcement with
each other. This can
force

condition, with the help

controlled
alloying

the powder metallurgy

the
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.
c) Physical Vapor Deposition:
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 iso-static pressing
In-Situ Processing
In-situ processing involves chemical reactions that result in the creation of reinforcing
phase within a metal matrix. The reinforcements can be formed from the precipitation in liquid or solid. This
method provides thermodynamic compatibility at the matrix reinforcement interface. The reinforcement
surfaces are also likely to be free of contamination and, therefore, a stronger matrix-dispersion bond can be
achieved
In situ Composite Materials
In situ metal matrix composites (MMCs) is multiphase material whose reinforcing phases are synthesized by
chemical reaction during fabrication, while a conventional ex-situ MMCs is fabricated by directly adding
reinforcements into its matrix. The in situ chemical process has several advantages over ex situ chemical
process, such as more homogenous reinforcement, excellent surface bonding, pure interphase, and appears
to be a suitable method for preparing metal–ceramic nano-composite.
In-situ and Ex-situ Techniques
 In-situ is multiphase material whose reinforcing phases are formed by chemical reaction during
fabrication.
 Ex-situ is fabricated by directly adding reinforcements into its matrix.
The driving forces for metal matrix composites is, of course, enhanced stiffness and strength of resulting
material
Fig: stirring of
composite melts Liquid state processing:
with ceramic Metal matrix composites can be processed by incorporating or
combining a liquid metal matrix with the reinforcement.
particles to There are several advantages to using a liquid phase route in
minimize settling of processing. These include near net-shape (when compared to solid
the particles during state processes like extrusion or diffusion bonding)), faster rate of
processing processing, and the relatively low
temperatures associated with
melting most light metals, such as Al and Mg. The most common liquid
phase processing techniques can be subdivided into four major categories.
Casting
Casting of MMCs can typically be accomplished with conventional
equipment used to cast metallic alloys. It is typically used with particulate
reinforcement because of the difficulty in casting fibrous performs without
pressure. The particles and matrix mixture are cast into ingots and a
secondary mechanical process, such as extrusion or rolling, is applied to the composite
a) Stir Casting
Particulate reinforcements are mixed with liquid metal melt and the mixture then solidifies. Specifically, the
pre-treated particles are inserted into the vortex of molten alloy, which is created by rotating impeller. A
problem arises during the stir casting process as the reinforcements are not uniformly distributed and form
sediments in the molten alloy. Generally, up to 30% particles in the size of 5-100 micrometer can be
incorporated into the metal alloy. An example of this method is Al-(10-
15%) B4C MMCs. In another variant of the stir casting method, particles
are introduced into the metal alloy in the semi-solid state.
b) Squeeze casting
Molten metal is introduced into an open die. The dies are then closed so
that the molten metal solidifies under pressure within the dies. The heat is
rapidly transferred from the molten metal to the dies under high pressure
and through the contact between the metal and the die surface. As a
result, a fine-grain casting with little to no pore is produced using this method.

c) Infiltration Process:
Liquid metal alloy is infiltrated into the porous forms of fibers/whiskers reinforcements. The volume fraction
of the reinforcements usually ranges from 10-70%, depending on the level of porosity. Silica and metal-based
mixtures are often employed as binder to retain the integrity and shape of the porous forms.
Another pressure less infiltration process consists of reactive or non-reactive infiltration of a reinforcement
preform. In this process particulate or fibrous filler is infiltrated with pure A1 or A1-Mg alloy. Alloy matrices
may also be formed in this process. For example, when pure A1 is intermingled with Mg particles (in addition
to the ceramic reinforcement particles) an AI-Mg alloy matrix is formed. The process is conducted in N 2
atmosphere to minimize interfacial reactions,
particularly since the pressure less process
involves long infiltration times at high
temperatures. When pure A1 is infiltrated,
the infiltration temperatures are between
700-800°C, while infiltration of A1-Mg alloys is
conducted between
700-1000°C (Lloyd, Schematic of squeezes casting process
1997). Typical
infiltration rates are less than 25 cm/h.
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.

Pressure less infiltration of MMCs:

(a) Alloy matrix infiltration of particulate preform and
(b) Pure matrix infiltration of metallic alloy particle and ceramic particulate preform

d) 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
Table ….
Assignments
1. Students have to solve --------------
2. Students have to solve --------------

Schematic of
squeezes casting
process.