UNIT IV - PROCESSING OF METAL

MATRIX COMPOSITES
 Session Meta Data

Author Dr. L. Poovazhagan

Reviewer

Version Number 1.2

Release Date 1 March 2020

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 Revision History

Revision Date Details Version

no.
10 February 2019 Describing the various processing methods of metal matrix 1.2
composites

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 Session Objectives
• Understanding the various types metal matrix materials

• Understanding the various processing methods of metal

matrix composites

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 Session Outcomes
• At the end of this unit, students will be able to

– Explaining the various types of metal matrix materials (K2:U)

– Explain about processing methods of metal matrix composites

(K2:U)

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 Agenda

Metal matrix materials

Processing methods of metal matrix composites

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 Metal matrix composites (MMCs)
• Metal matrix composites consist of a metal or an alloy as
the continuous matrix and a reinforcement that can be
particle, short fiber

There are three kinds of metal matrix composites (MMCs)

• Particle reinforced MMCs

• Short fiber or whisker reinforced MMCs
• Continuous fiber or sheet reinforced MMCs or whisker,
or continuous fiber.

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 Reinforcements used in MMCs

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 Metallic matrices
• Aluminium, titanium, magnesium, copper alloys
• Intermetallic Compounds

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 Processing of MMCs
• liquid state
• Solid state
• in situ fabrication techniques
• diffusion bonding
• powder metallurgy techniques

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 liquid state processing

• Casting, or liquid infiltration

• Squeeze casting, or pressure infiltration
• Centrifugal Casting

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 Schematic of the Duralcan process

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 (a) Press forming of a preform. (b) Suction
forming of a preform

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 Squeeze casting technique

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 Schematic of the spray forming process

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 Solid State Processes
• Diffusion bonding
• Several deposition techniques are available: immersion
plating, electroplating, spray deposition, chemical vapor
deposition (CVD), and physical vapor deposition (PVD)

• In Situ Processes

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 Schematic of diffusion bonding process

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 In-situ composites

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 Interfaces
in MMCs
• Major Discontinuities at Interfaces in MMCs

• Bonding. A ceramic reinforcement will have an ionic or a mixed ionic/covalent

bonding, while the metal matrix will have a metallic bonding.

• Crystallography. The crystal structure and the lattice parameter of the matrix
and the reinforcement will be different.

• Moduli. In general, the elastic moduli of the matrix and the reinforcement will be
different.

• Chemical potential. The matrix and the reinforcement will not be in thermodynamic
equilibrium at the interface, i.e., there will be a driving force for a chemical reaction.

• Coefficient of thermal expansion (CTE). The matrix and the reinforcement will,
in general, have different CTEs.
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 Interfacial Bonding in Metal Matrix
Composites
• Crystallographic Nature
• Mechanical Bonding
• Chemical Bonding

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 Major Discontinuities at Interfaces in MMCs
• • Bonding. A ceramic reinforcement will have an ionic or a mixed
ionic/covalent bonding, while the metal matrix will have a metallic bonding.
• • Crystallography. The crystal structure and the lattice parameter of the
matrix and the reinforcement will be different.
• • Moduli. In general, the elastic moduli of the matrix and the reinforcement
will be different.
• • Chemical potential. The matrix and the reinforcement will not be in
thermodynamic equilibrium at the interface, i.e., there will be a driving force
for a chemical reaction.
• • Coefficient of thermal expansion (CTE). The matrix and the reinforcement
will, in general, have different CTEs.

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 Interfacial
reaction products in some
important MMCs

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 Mechanical properties
• Modulus
• Strength
• Effect of Thermal Stresses

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 Strengthening mechanisms

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 • Properties of In Situ Composites
• Properties of Particulate Composites
• Thermal Characteristics
• High Temperature Properties, Creep, and Fatigue

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 Machining of MMCs
• Effects of Tool Selection
Cemented Carbide Tools
Polycrystalline Diamond Tooling
Chemical Vapour Deposition Tooling
Cubic Boron Nitride Tooling

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 Effects of Machining Parameters
• Cutting Speed
• Effect of Feed Rate
• Effect of Cutting Depth
• Built-Up Edge
• Effects of Coolant Selection

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 Applications of MMCs

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 Applications of MMCs

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 Recycling of Metal Matrix Composites
• There are two aspects of recycling MMCs\

• Recycling of MMCs as MMCs, i.e., without separating

the reinforcement from the matrix. This can be quite
economical where it is possible to use.

• Recovery or reclamation of the original components by

separating them via the use of fluxing materials that
have lower surface energies with the ceramic
reinforcement than with the metal matrix is a viable
option.

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 Summary
• Classification of metal matrix composites.
• Processing of metal matrix composites
• Interfaces in MMCs
• Mechanical properties of MMCs
• Machining of MMCs
• Applications of MMCs

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 Test your understanding
1. Classify metal matrix composites?
2. Explain the various processing methods of metal matrix
composites.
3. Write about the Interface between metal matrix and
reinforcement.
4. How to recycle the MMCs?
5. Write the applications of MMCs.
6. How to machine MMCs?

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 References
• 1. Krishnan K Chawla, Composite Materials: Science and Engineering, International Edition,
• Springer, 2012.
• 2. Mallick, P.K. and Newman.S., Composite Materials Technology, Hanser Publishers, 2003.

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