Manufacturing Methods

Hand lay-up Method

Spray Lay up Method
Injection Moulding
Pultrusion Method

Hand lay-up Method

Spray Lay up Method

Injection Moulding

Pultrusion Method

Metal Matrix Composites (MMC)

Metal matrix composites (MMCs), as the name
implies, have a metal matrix. Examples of matrices in
such composites include aluminum, magnesium, and
titanium.
Typical bers include carbon and silicon carbide.
Metals are mainly reinforced to increase or decrease
their properties to suit the needs of design. For
example, the elastic stiffness and strength of metals
can be increased, and large coefcients of thermal
expansion and thermal and electric conductivities of
metals can be reduced, by the addition of bers such
as silicon carbide.

Fabrication Method
Fabrication methods for MMCs are varied. One method
of manufacturing them is diffusion bonding, which is
used in manufacturing boron/aluminum composite parts.
A ber mat of boron is placed between two thin aluminum
foils about 0.05 mm thick. A polymer binder or an acrylic
adhesive holds the bers together in the mat. Layers of
these metal foils are stacked at angles as required by the
design. The laminate is rst heated in a vacuum bag to
remove the binder. The laminate is then hot pressed with
a temperature of about 500C and pressure of about 35
MPa in a die to form the required machine element.

Squeeze casting

Stir casting

Ceramic Matrix Composites (CMC)

Ceramic matrix composites (CMCs) have a
ceramic matrix such as alumina, glass, carbon
reinforced by bers such as carbon, silicon
carbide, boron carbide.

Processing
Ceramic Matrix Composites (CMCs)
Slurries: for continuous fibre reinforced
1 Fibers (glass fibers),
composite
impregnated with slurry (powder
glass (1-50m) in water and
water soluble resin binder), are
wound on to a mandrel to form
a tape.
2) The tape is cut into pies.
3) The types are stacked (layup).
4) Burnout of the binder
5) Heat pressure
e.g. glass fiber reinforced glassceramic matrix)
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Characteristics of Fiber-Reinforced Composites

Many factors must be considered when designing a fiber-reinforced composite
including the length, diameter, orientation, amount and properties of the fibers and
matrix, and the bonding between the fibers and matrix.
Fiber length and diameter: Fiber dimensions are characterized by their aspect ratio
l/d where l is the fiber length and d is its diameter.
The strength improves when the aspect ratio is large.
Typical fiber diameters are from 10 m to 150 m.
Fibers often fracture because of surface imperfections. Making the diameter small
reduces its surface area, which has fewer flaws.
Long fibers are preferred because the load carrying capacity is less at the ends than
the remainder. Thus the longer the rod, the fewer the ends, the higher the load
carrying capacity.

Different Forms

Effect of fiber Orientation

Maximum strength is obtained when
long fibers are oriented parallel to the
applied load.

Effect of fiber orientation on tensile strength of E-glass fiber-reinforced

epoxy composite.

Effect of fiber Orientation

The properties of fiber composites can be tailored to meet different loading
requirements. By using combinations of different fiber orientation quasiisotropic materials may be produced

Figure (a) shows a unidirectional arrangement. Figure (b) shows a quasi-isotropic arrangement

Advantages:

High strength to weight ratio (low density high tensile strength) or high specific
strength ratio!
High creep resistance
High tensile strength at elevated temperatures
High toughness
Generally perform better than steel or aluminum in applications where cyclic loads
are encountered leading to potential fatigue failure (i.e. helicopter blades).
Some composites can have much higher wear resistance than metals.
Corrosion resistance

Nature of Composites:

Disadvantages :

Material costs
Fabrication/ manufacturing difficulties
Repair can be difficult
Operating temperature can be an issue for polymeric matrix (i.e. 500 F). Less an
issue for metal matrix (2,700 F).
Inspection and testing typically more complex.