UNIT-III

Metal Matrix Composites

Lecture-1

08/19/15

Metal Matrix Composites

Characteristics of MMCs, Various types of Metal matrix
composites,
Effect of reinforcements on properties
Volume fraction Rule of mixtures,
Processing of MMCs - Liquid state processing stir casting, squeeze casting, infiltration, solid state processing
- Powder metallurgy, diffusion bonding,
In situ processes, applications of MMCs

Polymer Matrix Composites

Syllabus
Processing of polymer matrix composites
Hand lay-up, Spray lay-up processes,

Introduction&

Compression molding-

Types of MMCs

SMC Reinforced reaction injection molding,

Resin transfer molding,

Pultrusion, Filament winding,

Applications of polymer matrix composites

Introduction
A metal matrix composite (MMC) is composite material with at
least two constituent parts, one being a metal.
The other material may be a different metal or another material,
such as a ceramic or organic compound.
When at least three materials are present, it is called a hybrid
composite

Composition
MMCs are made by dispersing a reinforcing material into a metal matrix
The reinforcement surface can be coated to prevent a chemical reaction
with the matrix
Example:
carbon fibers are commonly used in aluminum
carbon reacts with aluminum to generate a brittle and water-soluble
compound Al4C3 n the surface of the fiber.

To prevent this reaction, the carbon fibers are coated with nickel or
titanium boride.

Matrix
Matrix is a ductile material
The matrix is usually a lighter metal such as aluminum, magnesium, or
titanium, and provides a compliant support for the reinforcement.

In high-temperature applications, cobalt and cobaltnickel alloy

matrices are common

Types of MMCs
Fiberreinforced
Particlereinforced
DispersionStrengthened

Fiber reinforced
Fibers

Diameters range from .0001 in to about .005 in depending on the

material.

Generally circular in cross-section, but can also be in the form of

tubular, rectangle, hexagonal.

Fibers used can be either continuous or discontinuous

Continuous fibers are very long; in theory, they offer a
continuous path by which a load Can be carried by the
composite material
Discontinuous fibers are short lengths

Fibers come in three forms

Whiskers (graphite, SiC, Si3N4, Al2O3)
Single crystals
Huge length/diameter
Small, so nearly flaw free
Strongest known materials
expensive
Fibers (aramids, glass, carbon, boron, Si3N4, Al2O3)
Polycrystalline or amorphous
Small diameter
Wires (usually metals)
Large diameter

Fiber Reinforcements
Composite strength depends on
following factors:

Inherent fiber strength, Fiber length, Number

of Flaws
Fiber shape
The bonding of the fiber (equally stress
distribution)
Voids
Moisture (coupling agents)

Particle Composites

Particles usually reinforce a composite equally in all directions

(called isotropic). Plastics, cermets and metals are examples of
particles.

Cermets
(1) OxideBased cermets

(e.g. Combination of Al2O3 with Cr)

(2) CarbideBased Cermets
(e.g. Tungstencarbide, titaniumcarbide)

Metalplastic particle composites

(e.g. Aluminum, iron & steel, copper particles)

Metalinmetal Particle Composites and

Dispersion Hardened Alloys

(e.g. Ceramicoxide particles)

DISPERSION STRENGTHENED MMCS

These composites have little or no interaction between the two

components and the particulate reinforcement is not soluble in the
metal matrix.
The dispersoids are usually 10-250 nm diameter oxide particles
They are located within the grains and at grain boundaries but are not
coherent with the matrix as in precipitation hardening
Dispersion

strengthened

alloys

are

somewhat

weaker

than

precipitation hardened alloys at room temperature but since over

aging, tempering, grain growth or particle coarsening do not occur on
heating, they are stronger and more creep resistant at high
temperatures.

EXAMPLES OF DISPERSIONED
STRENGTHENED MMCS

Pbo

REGULAR PARTICULATE MMCS: CEMENTED CARBIDES (CERMETS)

Cemented carbides are an example of regular particulate MMCs.
Co-WC cermets are produced by pressing Co and W powders into
compacts, which are heated above the melting point of Co.
On cooling the WC particles become embedded in the solidified Co,
which act as a tough matrix for the WC particles.
In addition to its strength and toughness, Co is also selected because it
wets the carbide particles to give a strong bond.

Other ceramics such as TaC and

TiC are also used to make
Cermets.
Microstructure of WC-20% Co
cermet (x1000)

CEMENTED CARBIDES
(CERMETS)
Cemented carbides are commonly used as inserts for cutting tool
inserts

Cutting tool inserts

milling
tool

lathe
tool

Im sure youve seen these in the machine shop.

This hard ceramic is very brittle so cracks or chips under impact
loads.

PARTICULATES MMCS FOR ELECTICAL CONTACTS

The highly conductive metals such as Cu and Ag are relatively soft and thus show
excessive wear when used in switches and relays resulting in arcing and poor
contact.
Ag reinforced with W particles has reasonable conductivity with excellent wear
properties.
The composite is made in two stages:

A low density W compact with interconnected pores is first produced by

pressing and firing tungsten powders.

Liquid silver is then infiltrated into the connected voids under vacuum

PARTICULATES MMCS FOR ELECTRICAL CONTACTS

Production of Ag-W electrical contacts
a) Pressing of W powders to form compact
b) Sintering of pressed compact to form open pore structure
c) Infiltration of liquid silver into the open pore structure.

Advantages of MMCs
* Higher temperature capability
* Fire resistance
* Higher transverse stiffness and strength
* No moisture absorption
* Higher electrical and thermal conductivities
* Better radiation resistance
* No out gassing
* Fabricability of whisker and particulate-reinforced MMCs with
conventional metalworking equipment.

Disadvantages of MMCs
* Higher cost of some material systems
* Relatively immature technology
* Complex fabrication methods for fiber-reinforce systems
(except for casting)
* Limited service experience