Materials

Processing
Technolo
ELS EVI E R

Journai of Materials Processing Technology 67 (l~,~97) 13 1g

The production and evaluation of metal-matrix composite castings

produced by a pressure-assisted investment casting process
C.S. Lira, A.J. Clegg *
Departnwnt of Manu/~tcttir#tg Engh:eering, Loughhorough Lhmer.sitv. L~,ughhorott~h, Lcics. LEI I 3TU. UK

Abstract
A process for the production of aluminium alloy metal-matrix composites ( M M C s ) by the liquid metal infiltration route is
presented. This process was based on investment casting to enhance its ability to cast complex shapes by the fibre prefonla

infiltration method. Squeeze casting has been the most popular route for producing such composites due to its ability to provide
high positive pressures to promote infiltration and good bonding characteristics of the fibre preform. However, squeeze casting has
limitations in respect of die design and complexity. This new process, referred to as the 'hybrid process" in this paper, combines
the advantages of the squeeze casting and investment casting processes. Tensile test results of as-cast specimens at room
temperature are reported for the investment casting, squeeze casting, and hybrid casting processes. The hybrid casting process
produced MMCs with tensile strengths equal to 80',of those obtained in squeeze infiltrated composites produced at the optimum
processing conditions. The AI-7"/,,Si alloy and ~-A1203 short fibre composite system was used for this work. ~ 1997 Elsevier
Science S.A.
Keywords: Metal-matrix composite: Investment casting: Squeeze casting

1. Introduction

Low density metals and alloys, such as aluminium.

magnesium, titanium and their alloys, have been popular matrices for metal-matrix composites (MMCs). Liquid metal infiltration of such matrix alloys into a wide
variety of ceramic, boron and carbon reinforcements
has been a popular route for producing such MMCs.
Wettability of such reinforcements by these light metals
and their alloys is unfortunately poor and deleterious
reactions at the matrix-fibre interface can produce a
brittle intermetallic compound which would decrease
the mechanical strength of the composites. Special procedures, such as pressure-assisted liquid metal infiltration techniques described by Clegg [1], were developed
to overcome wetting problems found in conventional
metallurgical methods. Such infiltration methods have
the ability to produce composite castings with the reinforcements restricted to selected locations.
The first commercial trials using high squeeze pressures to infiltrate an aluminium alloy melt into a porous
ceramic preform were carried out by Toyota Motor
* Corresponding author.
0924-0136/97/$17.00 1997 Elsevier Science S.A. All rights reserved.
PII S 0 9 2 4 - 0 1 3 6 ( 9 6 ) 0 2 8 1 0 - 5

Corporation in the early 1980s [2]. This development

enabled the historic manufacture of composite pistons
for use in automotive diesel engines to provide a higher
wear resistance to the piston ring grooves. The high
applied pressures produced good infiltration and bonding of the fibre preforms, thus providing aluminium
composite pistons that were superior when compared to
conventional pistons.
Thus, squeeze infiltration is an effective process for
achieving good casting integrity. It is, however, limited
in the complexity of castings that can be produced.
Investment casting is well known for its ability to
produce castings with complex shapes. Thin sections are
easily produced by this casting route due to the lower
thermal conductivity of the ceramic investment mould
as compared to the steel dies used in squeeze casting. In
order to overcome the squeeze infiltration limitations
and to enhance casting complexity the hybrid process,
based on investment casting, was adopted for the production of MMCs via the liquid metal infiltration route.
The process permits fibre preform infiltration by an
aluminium alloy melt without the need to alter the
chemical compositions of the constituents as is required
by the pressureless infiltration processes [3].

ii!iii~/i~i!!!ii,~ii!i~:~ii!~:!~i!:~ii!i~/~;~?
i!;i?,~' ~i~ill, ?~ ;;:~ ~ ~i ,,~,,~~ < ~ ?~/,, ~ /

....

....

C.S, Lim, A;J, C/egg/Journal of Materials Processing Technology 67 (1997) 13-18

14

TELESCOPIC--,.
CQLUMN

~PUNCH

'

''

.5 ~

i
LIQUII~

BAND H E A T E R ~ ]

METAL

CERAMIC

BOLSTER

FIBRE
PREFORM
REFORI

~- -

Fig. 1. Schematicdiagram of the hybrid casting set-up.

2. E x p e r i m e n t a l

The squeeze infiltration process was carried out by a

backward extrusion motion. The aluminium-silicon alloy was heated to 750+_10C and the preform to
400C. The applied pressure was 100 MPa, and the ram
speed was 9 mm s - ' . The pressure was maintained for
60 s during solidification.
For the developed hybrid process, composite production began with the incorporation of the fibre preform
within the wax specimen. A wax tree was then built up
and dipped in a proprietary impermeable, aluminium
resistant coating. The coated wax tree was 'flasked' into
a solid mould, dried, dewaxed and fired to 1000C. The
sintered ceramic mould was inserted in a die steel
bolster and stabilized at 250C. A schematic diagram of
the hybrid casting process set-up is shown in Fig. 1.
The aluminium alloy was poured into the bolster and
pressurised by a preheated punch until the metal solidified. Squeeze pressures of up to 15 MPa were applied
in this study. The punch was withdrawn and the ceramic block and casting extracted from the die. The
ceramic investment was removed by shattering to reveal
the casting.

procedure

The composite specimens were composed of an aluminium alloy matrix (AI-Si) and 10% volume fraction
delta-Al203 reinforcement short fibres held together as
a compact with a water-based silicate binder. The
chemical composition of the matrix was (wt%): 6.9% Si,
0.18% Cu, 0.49% Mg, 0.02% Ni, 0.04% Zn, similar to
BS1490 LM25. The alumina fibre preforms were provided by Thermal Ceramics pie., UK. The average fibre
diameter was reported to be approximately 3 ~tm. Prior
trials on these fibre preforms, taken from various sections of the fibre preform board and squeeze infiltrated,
showed an even distribution of fibres and a high level of
consistency of volume fraction. These trials indicated
that the fibre preforms from this batch were consistent
a n d capable of producing repeatable, accurate results.
Composites were fabricated by squeeze infiltration of
liquid metal in the direct squeeze infiltration process
a n d the developed hybrid casting process. For the
squeeze infiltration process, a 100-tonne hydraulic press
and a three finger-pronged cylindrical die were used.

r'LV

z)

", - , [

b') ',Y ".J i.,,'.

5p tm
(a)

'

'

5Ortm
(b)

"

'

(c)

Fig. 2. Optical micrographs of a unreinforced alloys produced by: (a) investment casting; (b) hybrid casting; and (c) squeeze casting.

C.S. L#~I, A.J. Clegg ,Journal o/Materials Processing Technology 67 (1997) 13-18

15

50~m
Fig. 3. Optical micrographs of: (a) hybrid cast composites; (b) squeeze infiltrated composiles.

Test castings were produced in the unreinforced alloy

by each of the three processes. Results of tensile tests
on these castings were compared with those obtained
from castings produced in the reinforced alloy. Round
cross-sectioned tensile specimens, as specified by the
standard Hounsfield specimen, were machined from the
castings. Ambient temperature tensile tests were
performed using a hydraulic mechanical tensile test
machine. All specimens were tested in the as-cast
condition.
Microstructures, taken from the tensile test
specimens, were examined under conventional optical
microscopy. The fracture surfaces of squeeze infiltrated
and hybrid infiltrated MMCs were examined under
scanning electron microscopy (SEM) to detemaine
fibre/matrix bonding by observing fibre pull-out.

3. Results and observations

3.1. Structure
The three optical micrographs, in Fig. 2, show the
structures of the unreinforced alloys produced by each
of the specified processes. The microstructure of the
investment cast hypoeutectic alloy (Fig. 2(a)) revealed
an essentially primary ~-AI dendritic structure. Dark
grey eutectic of ~-AI/Si forms very coarsely within the
interdendritic regions of the ~-AI matrix. Black needles
of FeSiAI5, light grey intermetallic ~-(FeSiMnAI) and
dark chinese script Mg2Si constituents are also
observed. Microporosity was found to be widespread
throughout the microstructure. The microstructure of
the hybrid cast alloy (Fig. 2(b)) revealed a smaller
average dendrite size when compared to that for
investment casting. The hybrid microstructure was
typically that of a finer interdendritic u-Al/Si eutectic
formed within a dendritic primary ~-Ai phase. Script
~-(FeSiMnAI) was observed in smaller quantities. No,
or very little trace of FeSiAI5 was found. Microporosity

was evident but somewhat less than that in investment

castings. The squeeze cast microstructure (Fig. 2(c))
was the finest of the three alloy microstructures. It was
observed to be a structure of very fine interdendritic
z~-A1/Si eutectic and primary ~-AI dendrites. The brittle
intermetallic ~-(FeSiMnA1) was less evident. Average
dendrite size was the smallest of the three
microstructures. Microporosity was not present within
the squeeze cast microstructure.
The optical micrographs for the reinforced alloys, see
Fig. 3, show that the alumina fibres were well and
evenly distributed in the aluminium alloy matrix. These
composites were infiltrated without signs of residual
porosity and exhibited a two-dimensional, random
distribution of alumina fibres for both the hybrid and
squeeze infiltration processes. There was no evidence of
severe damage of reinforcements caused by the high
applied pressure. The microstructures of the reinforced
alloys were essentially similar to those of the respective
alloy microstructures, but contained the reinforcement
fibres, and appeared to have slightly smaller average
dendrite sizes. The microstructure of the hybrid
reinforced alloy (Fig. 3(a)) revealed a larger average
dendrite size when compared to those of the squeeze
cast reinforced alloy (Fig. 3(b)).
Observation of the fracture surfaces of the MMC
tensile test specimens revealed the following. The
hybrid infiltrated and squeeTe infiltrated MMC
specimens both showed good fibre/matrix contact.
Although some fibre pull-out was observed, indicated
by crevices in the fracture surfaces, there were a!so
evidence of broken fibres with their stems remaining
bonded to the matrix. Fig. 4(a) and (b) show the SEM
photos of the hybrid and squeeze infiltrated MMC
fracture surfaces, respectively.

3.2. Mechanical properties

The highest mechanical properties were established
by optimising the processing conditions for the different

CS. Lira, A.J. C/egg/Journal of Materials Processhag Technology 67 (1997) 13-18

16

..............................

Fig. 4. Scanning electron micrographs of reinforced alloy test specimen fracture surfaces produced by: (a) hybrid infiltration; (b) squeeze
infiltration.

processes studied. It was not possible to produce composite castings by the liquid metal infiltration route
using the conventional investment casting process
throughout the range of processing conditions used.
Unreinforced alloys produced by the hybrid and
squeeze casting processes demonstrated higher mechanical properties when compared with those of conventional investment cast specimens. Tensile tests at room
temperature showed the ultimate tensile strength (UTS)
of the composites to be generally higher than those of
unreinforced alloy at the respective optimum processing
conditions. These results are presented in Table 1, and
are derived from an average of at least three tests using
repeatable conditions.
The results of the squeeze infiltration experiments,
see Fig: 5; show that the UTS increases with an increase
in fibre preform temperature, when other variables are
held constant. The results for the conventional investment casting process (unreinforced alloy), see Fig. 6,
show that the UTS decreases as the mould temperature
increases above 250C. The production of reinforced
castings by the hybrid casting process required that
both the ceramic mould and the fibre preform be
preheated to ensure infiltration. The results of these
experiments, see Fig. 7, show that the UTS at first
increases with an increase in mould temperature but
then declines.

4. Discussion

The hybrid, unreinforced properties of UTS, percentage elongation and Young's modulus were higher than
those of conventional investment casting by 16, 20 and
6% respcctively. However, these properties were only

80, 85 and 89% respectively of those obtained by

squeeze casting. These results are comparable with
those presented in the literature [4-6] and demonstrate
the advantage of pressure application duriv.g solidification. The infiltration of fibre preforms was attempted
without the use of chemical modification to either the
melt or preform. Within the scope of the experiments
conducted, it was not possible to infiltrate fibre preforms using the conventional investment casting process. Reinforcement produced modest improvements in
UTS and Young's modulus values for the hybrid cast
and squeeze cast material. These values were associated
with the expected reduction in ductility. The properties
of the hybrid material were, respectively for UTS,
percentage elongation and Young's moduius, 80, 75
and 92% of those obtained by squeeze casting. These
values again represent the benefits associated with the
higher level of pressure that can be applied during
solidification in squeeze casting. Although these results
show squeeze casting to be superior, they also demonstrate that it is possible to obtain an improvement in
the UTS and Young's m,~dialus values of cc,nventional
investment casting by incorporating a fibre preform and
applying pressure during solidification. The properties
of the hybrid reinforced alloy were, respectively, 22%
and 15% higher than those of the investment cast,
unreinforced alloy.
The high direct pressures of squeeze casting atzveared
to reduce or eliminate the presence of microporosity
within the casting (Fig. 2(c)), thus providing a high
casting integrity. Microporosity was evident in the investment casting (Fig. 2(a)), despite measures to ensure
that hydrogen levels were kept below 0.25 cubic ml per
100 g of the LM25 aluminium alloy melt. This suggests
that a conventional investment casting, poured under

C.S. Lira. A.J. Clcgg Jourmd ~:f Materials Processin.,. Techmdogy 67 ~1997) 13--IS

Table !
Mechanical properties of as-cast specimens at room temperature
U

Investment casting
Hybrid casting
Squeeze casting

nreiniorced

Reinforced

UTS (MPa)

Elongz-lion(':':,~

RA I'l~,~

E ~GPa}

UTS (MPal

Elongation C:,t

RA~";,)

E (GPa~

160
! 85
230

5
0
7

5
6
7

67
7t
80

195
245

......
1.5
2

1.5
2

77
84

atmospheric pressure and in air, would contain levels of

microporosity which would contribute to the reduction
in UTS. Microporosity in the hybrid casting was reduced, as shown in Fig. 2(b), by the applied pressure
maintained on the melt during solidification. However,
the relatively low applied pressure, compared to
squeeze casting, of the hybrid casting process did not
completely suppress microporosity and the process was
not capable of producing the casting integrity of
squeeze casting.
Structures of the specimens produced by the three
processes were observed to be significantly different,
with investment cast structures being the coarsest and
squeeze cast structures being the finest. The hybrid
process produced structures which were between the
coarsest and finest structure, as seen in Fig. 2(b). The
relative average size of the dendrite arm spacing as seen
from the three processes reflected their solidification
rates respectively. Correlations have been established
between measurements of average dendrite arm spacing
and solidification rate according to the exponential
relationship:

because of the tbrmation of more second phase interdendritic barriers to dislocation movement [8]. Thus,
squeeze casting, using high squeeze pressure and high
thermal transfer coefficient of the steel dies, gave the
highest UTS whilst investment casting, having the lowest thermal transfer coefficient and melt poured only
under atmospheric pressure, gave the lowest UTS.
From the microstructures, the increase in pressure applied to the solidifying melt, as seen fiom investment
casting to squeeze casting, appeared to reduce the brittle u.-IFeSiMnAI) intermetallic constituent. This partly
explains why ductility (both elongation and reduction
of area) increases with pressure application. The hybrid
casting process, with an intermediate level of pressure
application, demonstrated an intermediate ductility
when compared to squeeze casting (high end) and investment casting (low end).
SEM photos show that the levels of squeeze infiltration pressure applied in both the hybrid casting and
squeeze casting processes produce fibre preform infiltration and similar fibre/matrix contact. This may suggest
that the squeeze infiltration pressures used in the hybrid
process are sufficient to provide mechanical bonding.
This suggests that the lower UTS may be due to
reduced undercooling of the melt during solidification
and a slower solidification rate because of the lower
pressures used; and the lower thermal transfer coefficient of the flask investment mould, rather than bonding characteristics. This statement, however, does not
take into account any chemical action that might improve wetting due to the thermodynamic implications

2 = KR-"

where 2 is the average dendrite arm spacing (lam~. R is

the solidification rate (~tm s - ~), K is a constant, and n
is the exponent which is usually 0.3 to 0.4 [7]. Thus, the
relatively smaller dendrite spacing reflects a more rapid
solidification rate. This more rapid solidification rate
causes the size of the dendrite cells and their spacing to
decrease, thus giving a stronger and harder casting
250 [

.-

180

150 ' * ' * ~

A
t-t_

150
200

. . . . .
300
400

Preform Temp (D~.

Celsius}

120
200

if- 1 6 0 ~ / /

'

'

'

400

600

800

Shell Temp
(Dog. Celsius)

120

201)

300

400

PreforrrvMould Temp
(Deg. Celsms~

Fig. 5. Effects of the fibre preform temperature on the UTS for the squeeze infiltration process.
Fig. 6. Effects of the shell temperature on the UTS for investment casting.
Fig. 7. Effects of the preform/investment mould temperature on the UTS for hybrid casting.

18

C.S. Lira, A.J. Ciegg/Journal of Materials Process#ag Technology 67 (1997) 13-18

of pressure application [9]. Further work would be

needed to give some measure of fibre/matrix bonding.
The results obtained from reinforced castings produced by the hybrid process suggest that there is a critical
value for mould and fibre preform preheat temperatures.
For squeeze infiltration, the UTS value increased with an
increase in fibre preform preheat temperatures up to
400"C (die temperature constant at 250C). This confirms
that preheat temperature is an important factor in
ensuring effective preform infiltration [10]. However, in
the case of the hybrid process, the UTS value decreased
when the mould/preform preheat temperatures were
increased above 300C. These results appear to be
contradictory. However, when the results of the effect of
mould preheat temperature on the UTS of castings
produced by conventional investment casting are considered, an explanation can be established. Fig. 5 shows that
the UTS progressively decreases as the mould preheat
temperature is increased above 250C. This reduction in
the UTS can be attributed to the lower casting cooling
rate associated with higher mould preheat temperature
and the consequent coarsening of the primary ~-aluminium dendrites and eutectic silicon, see Fig. 2(a). In
the production of a composite casting by the hybrid
process there is a counteractive effect in operation. The
advantage of fibre preform preheat is counteracted by the
disadvantage of mould preheat. There appears to be a
critical temperature at which these opposing factors are
balanced. In these experiments the critical temperature
was 300C.

5. Conclusions

1. Selectively reinforced composites can be produced by

the hybrid casting process without any requirement
for chemical modification of the individual constituents used. The fibre preform can be incorporated

in the investment mould and infiltrated readily using

this method.
2. The UTS and Young's modulus values of unreinforced and reinforced material produced by the hybrid
casting process were significantly better than those of
the unreinforced material produced by the conventional investment casting process. However, these
values were inferior to those of squeeze cast material.
3. There appears to be a critical level of mould/preform
preheat temperature in the r~roduction of reinforced
material by the hybrid casting process. If this level
(determined in the experimeats reported to be 300C)
is exceeded, the UTS will decrease.
References
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UK, 1981, 84 and 8, 317--319.
1"2] T. Donomoto, K. Funatani, N. Miura and N. Miyake, Ceramic
reinforced piston for high performance diesel engines, SAE Int.
Congress and Exposition, Paper 830252, Detroit, 28 Feb.-4 Mar.,
Soc. of Automotive Engrs., Japan, 1983, pp. i-7.
[3] A.W. Urquhart, Novel reinforced ceramics and metals: a review
of Lanxide's composite technologies, Mater. Sci. Eng., USA,
A144 (1991) 75-84.
[4] R.F. Lynch, R.P. Olley and P.C.J. Gallagher, Squeeze casting of
aluminium, Die Casting Engrs., USA, 52 (1976) 14.
[5] T.W. Clyne, M.G. Bader, G.R. Cappleman and P.A. Hubert,
The use of 6-alumina fibres for metal matrix composites, J.
Mater. Sci., UK, 20 (1985) 85-96.
[6] R. Bartley, British and European Ahm~inium Casting Alloys-Their Properties and Characteristics, The Assoc. of Light Alloy
Refiners, UK, 1992, pp. ! 19-122.
[7] American Foundrymen's Society, Ah#ninium Casting Technology, American Foundrymen's Society, Inc., USA, 1986, p. 236.
[8] L. Edwards and M. Endean, Manufacturing with materials, in
Materials #~ Action, Butterworths, UK, 1990, p. 90.
[9] O.G. Epanchintsev, Structqre and properties of metals solidified
under high pressure, Russian Cast#lgs Production, Russia, i
(1972) 34-37.
[10] M.R. Jolly and G. Haour, Fibre ReinJbrcement of Alum#ram by
Squeeze Casting--A Summary of the State of the Art, Switzerland, 3 & 2, 1988, pp. 173-177.