Composite materials

 Composite materials (also called composition materials or shortened to composites) are materials
made from two or more constituent materials.
 Have significantly different physical or chemical properties, that when combined, produce a material
with characteristics different from the individual components.
 The individual components remain separate and distinct within the finished structure.
 The new material may be preferred for many reasons: common examples include materials which are
stronger, lighter or less expensive when compared to traditional materials.
 The most important advantage associated with composites is their high strength and stiffness along
with low weight
Historical perspective
 In 1939 glass fiber manufactured commercially for high temperature electrical application
 In 1950 boron and carbon fibers were produced for making ropes.
 In 1960 matrix was added to make a polymeric matrix composites;
 In 1970’s the cold war force developed metal matrix composites for military aircraft and missile
guidance systems
 In 1990s, high temperature ceramic matrix composites were being researched for use in next
generation of aircraft engines and power plant.
Shipments of composites

Classification of Composite by Matrix

 PMC: Polymer Matrix Composite  CMC: Ceramic Matrix Composite
 MMC: Metal Matrix Composite  CC: Carbon Composites
Metal Matrix Composite
 Matrix used in Metal Matrix Composite are Aluminum, Magnesium, Titanium, Cobalt, Cobalt-nickel etc
 Reinforcement used in Metal Matrix Composite are Alumina, SiC, Zirconia, TiN, CBN etc

Functions of the Matrix Material

 Provides the bulk form of the part or product made of the composite material
 Holds the imbedded phase in place
 When a load is applied, the matrix shares the load with the secondary phase, in some cases
deforming so that the stress is essentially born by the reinforcing agent
Functions of the Reinforcing phase
  Function is to reinforce the primary phase
 Imbedded phase Possesses most commonly one of the following shapes:
 Fibers  Particles  Flakes
Classification of metal matrix composites (MMC)

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Processing of metal matrix composites (MMC) e
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Processing of metal matrix composites (MMC) can be classified into
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 Solid State Processing
 Liquid State Processing
 In-Situ Processing

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 liquid
suspension. After blending, the mixture is further processed by cold compaction, canning, degassing, and high
temperature consolidation. This method is usually used for the processing of aluminum and magnesium metal
matrix composites.
Diffusion Bonding:
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.

Liquid State Processing

Stirr Casting: Particulate reinforcements are mixed with liquid metal and the mixture then solidifies.
Specifically, the pre-treated particles are inserted into the vortex of molten alloy, which is created by a
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.
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
Infiltration Process:
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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.
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

Different MMC systems

 Aluminum Matrix  Copper Matrix Composite

Composite (AMC) (CMC)
 Magnesium Matrix  Titanium Matrix Composite
Composite (MMC) (TMC)

Aluminum Matrix Composite (AMC)

 This is the widest group of MMC
 Matrices for AMC are usually Al-Si alloy
 Reinforcement material for AMC are
 Alumina (Al2O3)  SiC  Graphite
Continuous fibers of alumina, silicon carbide or graphite (long-fiber reinforced composites)
Discontinuous fibers of alumina (short fiber reinforced composite)
Preparation of AMC
Aluminum metal matrix composite are made by three processes.
1. One is power metallurgy root which is sintering process
2. Stir casting
3. Infiltration methods
Properties of AMC
The following properties are typical for AMC material.
 Possess high strength at elevated temperatures
 Have high modulus  High thermal conductivity
 Low density  Excellent abrasion resistance
Uses:
 It is used for manufacturing of automotive parts like pistons, pushrods, brake components, brake
rotors for high speed trains
 Bicycles are made out of metal matrix composite. Bicycles coming moved from steel frame to
aluminum frame where the weight reduction was there from aluminum today
 All the parts are made out of aluminum metal matrix composite.
 Golf clubs and the electronic substrates, cores of high voltage and electric cables are made out of it.

Magnesium Metal Matrix composite (MMMC)

Magnesium metal matrix composite is generally reinforced with SiC particles. The following properties are
typical for MMMC
  It is low of density  High wear resistance
 High stiffness  Good creep resistance
 Good strength at elevated temperatures
 It is used in manufacturing parts of racing cars automobile braking system, aircrafts gearboxes
transmission and compressors of engines.

Copper Metal Matrix Composite CMC

Copper matrix composite are reinforced by
 continuous fiber of carbon  Tungsten
 SiC  Stainless steel
The process for making copper metal matrix composite is powder metallurgy and infiltration same as was
described about magnesium matrix composite So, we have the same processes like powder metallurgy, stir
casting and infiltration for MMC also.
Properties of Copper Metal Matrix Composite
 low coefficient of expansion  conductivity
 high stiffness  high thermal conductivity
 good electrical  good wear resistance
 CMC are used for manufacturing of electronic relays, electrical conducting springs and other
electrical and electronic components

Titanium Matrix Composite TMC

Titanium matrix composite are reinforced mainly by
 Continuous monofilament silicon carbide fiber. (long fiber reinforced composite)
 Titanium boride TiB and TiC particles (particulate composite); this are the some of the particles
which can also be reinforced with titanium metal matrix composite predominantly
 TMC are manufactured by powder metallurgy root(sintering).
Properties of TMMC
The following properties are typical for TMMC
 High strength  High thermal stability
 High stiffness (modulus of elasticity)  High wear resistance
 High creep assistance  Light weight
Uses of TMMC
TMC are used for manufacturing of structural components of F-16, turbine engine components, high
temperature fan blade actuator pistons, synchronization rings, shafts, discs, automotive engine components,
drive train parts and other general machine parts are made out of titanium metal matrix composite.

General applications
Automobiles
 High temperature engine components
 Brake drum and rotors
 Bumpers and fenders
Aerospace
 Jet engine fan blades
 Space and satellite structures
 Helicopter transmission structures
Advantages
 Higher temperature capability
 Fire resistance
 Higher transverse stiffness and strength
 No moisture absorption
 Higher electrical and thermal conductivities Better radiation resistance

Disadvantages
 Higher cost of materials
 Complex fabrication methods for fiber-reinforced systems (except for casting)
Assignments
1. Describe stir castings methods used for the manufacturing of MMC material
2. What is the difference between particulate-reinforced composite material and long fiber composite
material