A LITERATURE REVIEW ON METAL MATRIX COMPOSITES
Abstract -In this review paper, the individual and multiple impacts of various
Aluminum metal matrix composites are discussed. Aluminium metal matrix composites
are mainly focused in this paper. The aluminum MMC’s has received extensive
concentration for basic and also for practical reasons. The individual and multiple
reinforcements with Aluminium metal matrix composite has gained various applications
in Aerospace, Automobile, Space, Defense, Electrical Equipments, etc., This is mainly due
to high strength and less weight properties. The addition of reinforcements in Matrix
improves specific strength, tensile, wear, fatigue properties and various properties. Many
researchers attempted different experiments with adding distinct reinforcement
materials and results in distinct property.
Key Words: Metal matrix, Reinforcement, Strength, Wear, Experiments, Property.
1. Introduction
Monolithic metal have disadvantages over combinations of strength, stiffness, density
and various mechanical and physical properties. To minimize these issues and to get
the significantly increasing demands of recent technology in engineering, metal matrix
composites are gaining great importance.
The combining of two or more materials in which one is matrix and another is
reinforcement results in Metal Matrix Composite. The best mechanical properties which
are not achieved by traditional materials are provided by Metal Matrix Composites. Metal
Matrix Composites have been substantially utilized in Space technology, automobile
industries, Aerospace, Marine e.t.c. due to their good mechanical properties such as
ductility, elastic modulus, hardness, wear resistance, tensile strength, tribological
properties combined with sufficient weight savings than matrix alloy materials. For
MMCs SiC, Al2O3, Gr, B4C, etc., is excessively applied particulate reinforcements. In
this literature review SiC is focused as reinforcement material with Aluminium as
Metal matrix and various techniques are used to produce metal matrix composites with
different SiC % resulted in distinct improved properties as per the process used.
Aluminium alloys are the predominant metal in automobile industries. The major
elements are copper, magnesium, manganese, silicon, tin and zinc respectively. The
most commonly used cast aluminium alloy system is Al-Si, Containing high levels of
silicon (4.0-13%) resulting in good casting characteristics. Aluminium possess
properties that make it extremely desirable engineering materials, it has low density,
good corrosion resistance in most natural environments, excellent specific strength, it
can be formed easily, possess low melting temperature, high thermal and electrical
conductivity and is non-toxic. Alloys of Aluminium are widely used in structures of
engineering and for light weight components, also for the applications where high
corrosion resistance is required. Alloys of aluminium have been very important in
aerospace component manufacturing, aluminium alloys are widely used in automotive
engines, particularly in cylinder blocks and crankcase to reduce the weight that is
possible.
Density 2.7g/cm3
Hardness(Brinell) 150-500Mpa
Ultimate tensile stress 500.8Mpa
Tensile yield stress 495.2Mpa
Young’s modulus 70Gpa
Machinability 70%
Shear strength 330Mpa
Melting point 660.30C
Literature Review
[1] SUBBARAYA MOHAN KUMAR et.al [2017] attempted the experiment to study the
microstructure and mechanical behavior of Al2021-3 wt. % of fly ash and Al2021-5 wt.
% of Fly ash composites made-up by squeeze casting technique. Here, composites are
manufactured by two stage stirring process to improve the wetting behavior and to
achieve better bonding between the Al2021 alloy matrix and Fly ash particulates. In the
present investigation Al-4.5 wt. % Cu alloy having theoretical density 2800 kg/m3 is
used as the base matrix. The chemical composition of the aluminium base matrix as
Cu-4.53%, Mg-0.05%, Si-0.15%, Fe-0.16%, Mn-0.07%, Zn-0.01%, Pb-0.01%, Sn-
0.01%, Cr-0.02%, Al-Balance. The chemical composition of Fly ash in wt. % are as
Al2O-30.40%, SiO-58.4, Fe2-8.4%, TiO2-2.75%, Loss on-1.43%.
The molten metal matrix Al-4.5% Cu alloy was stirred using a Stirrer to create a vortex
and 0.4wt.% of Mg was added to ensure good wettability and the preheated
reinforcement were added to the molten metal mixture with a continuous stirring
speed of 300 rpm to a time span of 5 minutes. The stirred molten metal mixture with
the reinforcement is poured into the preheated cast iron die and the die was placed in a
compression testing machine. The plunger is placed into a die and a load of 120Mpa
was applied for a minutes. The melt was then allowed to solidify in the moulds. The
vortex generated in the stirring process and squeezing action breaks the solid dendrites
due to higher friction between particles and Al matrix alloy, which further induces a
uniform distribution of particles.
Conclusion: The Al-4.5 wt% Cu alloy composites with different weight percentage
were successfully synthesized by Stir Squeeze Cast technique.
Hardness of Al-4.5 wt% Cu alloy composite was found to be more than base matrix.
The reinforcement of particles has enhance the tensile strength of aluminium matrix
from 153Mpa to 197Mpa.
U.T.S. of the composites were found to be higher than base matrix and Yield strength
of composite found to be higher than that of base matrix ( increased from 124Mpa to
157Mpa after addition of 5 wt.% of Fly ash particulates.
[2] H. KHOSRAVI et.al [2015] conducted an experiment on Al-Si casting alloy (A356)
with nominal compositions (mass fraction, %) of balance Al, 6.93 Si, .23 Mn, .26 Zn, .
38 Mg, .25 Cu and .11 Fe was used as the matrix material. The silicon carbide (SiC)
particles in the size range of 63-90 µm were used as the reinforcement. The Vibration
Cooling System consists of a cooling slope made of copper plate (1000mm × 120mm
×10mm) mounted on a steel frame. This assembly was fixed on a fixed plate and could
vibrate at different frequencies by means of a 3HP, 2840 r/min electrical motor.
Al-Si composites with various contents of SiC particles were fabricated by both the
compocasting and Vibration Cooling System methods. The matrix alloy was melted and
then its temperature was decreased to about 590ć while stirred at 800r/min using a
graphite impeller attached to a motor. At this stage, specific amounts of oxidized SiC
particles were added to the alloy at a rate of 50 g/min and the semi- solid slurry was
stirred for 20 min to obtain a uniform distribution of the SiC particles in the matrix. In
order to facilitate the casting of slurry, it was heated to 670ć and stirred at this
temperature for another 5 min. For producing the campocasting samples, the resultant
slurry was poured into a cast- iron die with the internal diameter of 80mm and a height
of 60mm. The V.C.S. samples were made by pouring the Al/SiC slurry onto the surface
of the cooling slope set at 45 degree inclined angle while it was vibrate at 65Hz of
frequency and 680 µm of amplitude. After travelling the distance of 400mm on the
cooling slope, the melt was poured in the same die as mentioned before. The samples
were examined by metallographic technique.
Result and Conclusions: The matrix of compocast- processed composites exhibited
a dendritic structure while the SiC particles were pushed to the interdendritic regions.
In the as-cast VCS composites, the SiC particles were dispersed uniformly between the
globules of α-Al phase. The increased SiC content resulted in decreased size at the
expense of decreased sphericity of globules and also improvement in uniformity in SiC
distribution. The increased SiC content resulted in decreased aspect ratio of eutectic
silicon particles, increased porosity level and increased hardness of both the compocast
and VCS samples. However, despite of the higher porosity content of the VCS samples,
they exhibited higher hardness values at any SiC particle content compared with their
compocast counterparts. The increased SiC content resulted in decreased wear rate and
friction coefficient of both the compocast and VCS samples. However, at any SiC
particles loading, the VCS-processed samples exhibited lower wear rates and smaller
friction coefficients as compared with their compocast counterparts.
[3] A.C. VIEIRA et.al [2009] the influence of centrifugal casting processing parameters
on the wear of Al alloy/SiC functionally graded composites was studied. A functionally
graded material (FGM) is a class of composite materials consists of two or more phases,
which varies in some spatial direction its composition and/or microstructure. A non-
commercial Al alloy (Al-10Si-4.5Cu-2Mg) was selected to be the mat of the composites
and the reinforcing particles were β-SiC with an average size of 37.8µm. Al-SiC
functionally graded metal matrix composites (FGMMC’) were centrifuged with radial
geometry, using two different mould rotating speeds 91500 and 2000 rpm). By
centrifugal casting a gradient in the distribution of SiC particles across the thickness of
the cast ring was obtained. The sliding wear behavior was studied using a ball-on-ring
configuration (sliding wear parameters: 3N, 0.5m/s, 1800 m, room temperature) with a
high-carbon chromium steel ball (AISI 52100) as counter body. A good correlation was
evidenced between the dry sliding behavior of functionally graded aluminium matrix
composites and the distribution of SiC reinforcing particles. The dominant wear
mechanism were identified and corrected with the microstructure of the FGM.
Conclusion: Centrifugal casting process promotes a gradient in the microstructure
and in hardness of the centrifuged unreinforced Al alloy due to differences of
solidification rates. This material was characterized by severe wear assisted by an
adhesive wear mechanism. FGM cast at low centrifugal speed presented a smooth
gradient on SiC distribution, while FGM cast at higher centrifugal speed revealed a
sharper gradient on the distribution of reinforcing particles. This gradient was
controlled by the movement of the solidification front, blocking the mobility of SiC
particles in the melt. The increase of SiC content up to approx 5% resulted in a fast
decrease of the FGM composite wear coefficient, followed by an additional, but much
slow, decrease of the wear coefficient values with the incorporation of SiC particles
above 5%. For the Aluminium based FGM composites considered in this study, two-
body abrasion wear, adhesion and delamination were the main wear mechanisms
identified.
[4] M.A. TRISHUL et.al [2020] involves the study of certain mechanical properties of
Aluminium 319 alloy before and after the addition of reinforcement. The reinforcement
materials used in this experiment are silicon carbide and fly ash. Aluminium 319 ingots
were cut into small blocks of 3 in; These Aluminium blocks are weighted in an
electronic weighting machine with a least count of .005 kg and then heated in a graphite
crucible which was loaded into an induction furnace maintained at a temperature of
approx 825 degree centigrade. Equal quantity of Silicon Carbide and Fly Ash particles
are weighted in accordance with the weight percentage of Al in the furnace to
accommodate pre-heating of then reinforcements. A motorized stirrer was rotated at 85
rpm and silicon carbide was added slowly while stirring in small quantities and was
followed by addition of reinforcement the crucible was stirred for 300 s. The melt was
then poured using a gas burner, to obtain rods. The procedures were performed for
weight % of 3%, 3.5%, 4%, 4.5%, 5% of SiC and fly ash. Various tests were performed
after final production of composites and following conclusions came out.
Conclusion: The young’s modulus of composite was found to decrease with increase
in percentage reinforcement, but increase in percentage beyond 4% increase the
modulus. The hardness of the composite increases and there has been an maximum
increase of 4.6% for 4% composition and then the hardness was found to decrease and
the hardness decreases by 4% for 5% composition, the dendrites for lower % have
sharp edges which contributes to increase in hardness. The density of the composite
was found to be varying as the % reinforcement was increased. The composition of 3%,
4% and 5% exhibit density below that of the parent material and composite 3% has the
lowest density. Composites 3.5% and 4.5% exhibit higher density than the parent
material, and composite 4.5% posses the maximum density increase of up to 2%. Free
vibration test of the composites are performed and the theoretical and practical natural
frequencies are found to be in close proximity with each other. 3% composition
exhibits highest natural frequency with increase of 5.5% and then the frequency
decreases with increase in percentage reinforcement. The damping ratio was found to
decrease and as the composition was increase beyond 3.5% the damping ratio
increases but although was less than the parent material. The least damping was
exhibited by 3.5% composition with a percentage decrease of 5.5 % and then the
damping increases by 37% for 5% composition.
By analyzing all the obtained results, we can conclude that the 5% SiC + 5% fly ash
composite could be used in certain applications where hardness of the material and
reduction of vibration is concerned.
[5] N.P. HUNG et.al [1995]. This study investigates the machinability of cast and
powder- formed aluminium alloys reinforced with SiC particles. Models for tool wear
are validated, while the effect of tool materials, particle distribution and sub-surface
damage are studied and compared. The cast MMC consists of A359 (Al 9.27 wt% Si,
0.15 Fe, 0.55Mg) as matrix and 19.2vo% SiC (22 wt %) as reinforcement. Φ18mm bars
were fabricated by the permanent- mold casting technique. Pouring temperature 700-
710 degree Celsius, average stirring rate 250rpm. No subsequent heat treating. The
Powder- formed MMC consists of L2 (Al 2.5 wt%, 2.0 Cu, 1.0 Mg, 0.15 Zr) powder as
metal matrix and 20wt% SiC as reinforcement. Φ10mm bars were fabricated by mixing
matrix and particulate powders, cold isostatic pressing at 3700 bars, extruding at 500ć
temperature, 10:1 ratio, 0.01m/s speed, water quenching at extrusion exit.
Roughing with uncoated tungsten carbide inserts then finishing with polycrystalline
diamond tools is the most economical route to machine SiC reinforced MMCs exhibits
higher machinability than that of the powder- formed MMC mainly because of the
favorable shape and distribution of the particles, but weakly because of the fabricating
processes. Regardless of the cutting tool materials used for machining, cracked SiC
particles and debonded matrix- reinforcement interface were found underneath a
machined surface. Such machine-induced defects could be a concern when using the
MMCs in a critical application
Conclusion: Facing is preferred over turning when studying machinability of MMCs
since facing requires much less material for machining. Roughing with uncoated WC
inserts and finishing with PCD tools are recommended to machine Al-SiC MMCs for
the indicated cutting conditions. Distribution and shape of SiC have little effect on tool
lives of the TiN coated and uncoated HSS or WC, but significantly affect the
performance of the CBN and PCD tools. This is due to the relative difference between
the hardness of the SiC reinforcement and the respective tool materials. The difference
in machinability is weakly dependent on the casting or powder- forming processes.
Surface integrity of the powder-formed MMCs and cast MMCs are affected by particle
fracture, interfacial delamination, particle pull out and matrix work-hardening. In
addition, the collapsed and machined through voids are found just underneath or
along a machined surface of the cast MMCs. All of these machine-induced defects
might be a concern when the MMCs are used in a critical application.
[6] GOPAL KRISHNA U B et al.[2013], By liquid casting technique, aluminum metal
matrix was strengthen with boron carbide particulates of 37, 44, 63, 105, 250µ sizes
separately. The mechanical and microstructure properties of the manufactured AMCs
were examined. In view of the outcomes acquired from tensile strength of the alloy
composites of various sizes, 105µ size B4C was picked and changed the wt% of B4C
with 6,8,10 and 12wt%. The miniaturized scale vicker's hardness of AMCs was observed
to be most extreme for the molecule size of 250µ and discovered greatest for 12 wt% if
there should be an occurrence of changing wt% of the fortification of 105µ size. The
tensile stress of AMCs was observed to be most extreme for the molecule size of 105µ
and discovered greatest for 8 wt%. The Optical micrographic study and XRD
investigation uncovered the nearness of B4C particles in the composite with
homogeneous scattering.
From the above research paper I reasoned that the presence of such hard surface zone
of particles offers more protection from plastic twisting which prompts increment in
the hardness of composites. The expansion of B4C particles in the lattice prompts more
solidarity to framework compound by offering more protection from elastic loads.
[7] S. NOUROUZI et.al [2013] has successfully conducted an experiment to study the
effect of pouring and mould temperature, cooling slope, and length on the
microstructure of the A356 aluminium alloy is investigated and the best parameters are
selected to minimize the grain size. The A356 alloy was melted in a silicon carbide
crucible located at a resistance furnace. Then, the molten alloy was allowed to cool
down to the pouring temperature and was then poured on to the surface of a cooling
plate 100 mm wide with a maximum length of 700mm. The cooling plate was adjusted
at the different cooling lengths and cooling slopes. Also, various molds and pouring
temperature were employed in the experiments.
Conclusion: The dendritic primary phase in the microstructure of conventionally cast
alloy readily changes to a fine and non-dendritic structure by applying copper-made
cooling slope. The microstructure produced by the cooling slope depends on the
cooling and mould temperature. An optimum pouring temperature was observed in
which minimum size and maximum sphericity was created at a constant angle and
length. Increasing the mold temperature up to 200 degree Celsius causes globularly
and appropriate distribution of α-Al particles. When the mold temperature increases
up to 400 degree celsius, the globules of the α-Al phase become extremely large
compared with the microstructures of ingots produced with the mold temperature of 25
degree celsius and 200 degree celsius. These particles are not globular and the shape
factor also decreases. The proposed neural network can predict the average grain size
as well. A verification test has shown that the optimal values provide the best
microstructure.
[8] SUKANGKANA TALANGKUN et.al [2020] successfully conducted experiments to
investigate the production of an A356/SiC composite by a thixoforming. The composite
contained 15% by weight SiC particles of around 15-37 micro-meter in size as the
reinforcing phase. The composite feedstock was produced by semi-solid stir-casting,
where preheated SiC powder was gradually added into the A356 alloy melt to form a
continuously stirred slurry composite melt, which was then cast in a steel mold. For
thixoforming, the feedstock was heated to 583 degree celsius and its viscosity was
reduced with shear rate, implying that A356/SiC exhibits shear thinning or non-
Newtonian behavior. This is caused by the characteristics billet structure obtained
having relatively globular grains that accommodate the flow of semisolid composite. In
the rheo-casting process, the A356/SiC feedstock was re-melted at 610 to 615 degree
celsius prior to die- casting and the resulting slurry was injected into a die with
injection speeds of 3 and 4m/s and pressure of 11 and 12 MPa, respectively. Two work-
pieces of 16*15.6*205 cubic mm were produced in one shot and aged at 135 degree
celsius for 12 h. The results show that both speed and low pressure rheo-die-cast
samples exhibit uneven filling at the end of the part, whist both high pressure and high
speed promote more uniform distribution of SiC particles throughout the part length.
In the as-rheo-die-cast condition, the most uniform of microstructure and hardness
obtained from a sample fabricated at 4m/s speed and 12MPa pressure.
Conclusions: A stir casting in semi solid state, with a stirring aped of 300 rpm and
stirring time of 10 min, was successful in producing non-dendritic A356 alloy and
A356/SiC composite feedstock with good distribution of particulates in the matrix.
Shearing promotes near globular and rosette-like solid grains in the liquid phase,
which is suitable for subsequent semisolid forming. After thixoforming at 0.4 fraction
liquid, the microstructure of A356 alloy appeared to have more spherical grains without
liquid entrapped in a solid phase. At the same amount of particle loading, an increase
in reinforcement particle size increases the viscosity of the composite. An increasing
viscosity results in lower flow- ability and increase the liquid-solid segregation. The
hardness of the matrix phase in the T6 condition increased with the amount of
reinforcement phase. Composites with small-reinforcing particles exhibit greater
hardness at higher amounts of particles, while composites with large reinforcing
particles exhibited high hardness. In thixoforming, the feedstock thixoformed at 583
degree celsius, equivalent to 0.4 fraction liquid and viscosity is reduced with shear rate,
implying that the A356/SiC exhibits shear thinning or non-Newtonian behavior. This is
caused by the characteristic relatively globular grain structure of the billet that
accommodates the flow of the semi-solid composite slurry. The die pressure affects the
density of the castings. In the rheo-die-casting process, the A356/SiC slurry is die-cast
at 610 to 615 degree celsius. The most suitable die casting condition for semi-solid
A356/SiC composites appears to be that of 4m/s speed and 12 MPa die pressure,
respectively. This condition allows an even flow and uniform distribution of reinforcing
particles in the A356 matrix. There was no evident shrinkage porosity or gas
entrapment in the rheo-die-cast parts. This condition also exhibited uniform hardness,
resulting from the uniform microstructure of the sample, as compared to other
conditions.
[9] R.N. RAO et.al [2009] has present an effect of matrix alloy and influence of SiC
particle on the sliding wear characteristics of high strength aluminium alloy AA7010,
AA7009 and AA2024, composites was examined under varying applied pressure and a
fixed sliding speed of 3.35 m/s. The results revealed that the wear resistance of the
composite was noted to be significantly higher than that of the alloy and is suppressed
further due to addition of SiC particles. The overall observation among the matrix alloy,
AA7010 alloy shows maximum wear resistance than that of other and can withstand
the seizure pressure up to 2.6 MPa. The wear mechanism was studied through worn
surface and microscopic examination of the wear tracks. The wear mechanism strongly
dictated by the formation and stability of oxide layer, mechanically mixed layer,
subsurface deformation and cracking. The overall results indicate that the high
strength aluminium alloys and composite could be considered as an excellent material.
The strength at room temperature as well as elevated temperature is noted to be more
in 7010 alloy and 2024 alloy, the later one exhibited less strength at room temperature
as well as at elevated temperature.
Conclusions: Sliding wear behavior of the alloy and composites were studied as a
function of reinforcement volume fraction, matrix alloy for all the three matrix alloy
system. The wear resistance of the alloy is improved significantly due to particle
addition. The wear rate decreases with increase in SiC content irrespective of material.
2024 alloy system suffers from highest wear rate, where as the 7010 alloy system
exhibited least wear rate irrespective of SiC content and processing condition. Matrix
alloy and SiC reinforcement play an important role in controlling the wear behavior.
The coefficient of friction increases at an average rate of 0.123 per wt. % of SiC. The
seizure pressure of composites hardly affected when SiC content increases from 10 to
15 wt. %. Overall observation of subsurface of composite stated that the mode of
deformation is more or less same irrespective of the concentration of SiC particle. The
matrix flow is resisted by the particles and due to interaction of flow of matrix and SiC
particle, the later one tends to rotate leading to matrix flow of more randomly in the
surrounding area.
