Manufacturing Techniques of

Advanced Materials
Prof. D. Nageswara Rao,

Former Vice Chancellor of Centurion University of Technology and Management,

Retired Professor, Andhra University, Vishakhapatnam.

 Prof. D. N. Rao

History of Composites:-
Many of our modern technologies require materials with unusual combinations of
properties that cannot be met by the conventional metal alloys, ceramics, and polymeric
materials.
Humans have been making composite materials to fabricate more grounded and lighter
items for a large number of years. The primary utilization of composite is in 1500 B.C.
at the point when early Egyptian and Mesopotamian pioneers utilized a blend of mud
and straw to make solid and tough structures. Straw kept on giving support to antiquated
composite items including stoneware and water crafts.
Afterward, in 1200 A.D. the Mongols developed the primary composite bow. Utilizing a
mix of wood, bone, and "creature stick," bows were squeezed and wrapped with birch
bark. These bows were to a great degree effective and amazingly exact. Composite
Mongolian bows gave Genghis Khan military predominance, and in view of the
composite innovation, this weapon was the most capable weapon on earth until the
development of explosive.
 Prof. D. N. Rao

Composites: -
A composite material is the combination of two materials
one is called as reinforcing phase and another one is
matrix phase. Mechanical properties of composite
materials is mainly depend on size, shape, volume fraction
of reinforcement etc., The matrix phase which is present in
the composite material gives support and surround the
reinforcement material and also maintains their relative
position.
 Prof. D. N. Rao

Properties of The Phases:-

Has more ductile nature and less hard.
Matrix phase :
It is a primary phase and continuous character.
Supports the reinforcement materials and share the loads applied on it.

Reinforcement phase :
It is secondary phase and it is discontinuous form.
It is stronger than matrix phase.
 Prof. D. N. Rao

Types of Composites:-

The matrix composites are of three types:

Metal Matrix composites,

Ceramic Matrix composites,
Polymer Matrix composites.
Prof. D. N. Rao
 Prof. D. N. Rao

Composites in Action:-
 Prof. D. N. Rao

Composite Structures:-
 Prof. D. N. Rao

Metal Matrix Composites (MMC):-

Metal Matrix Composites are made out of a metallic framework
(aluminum, magnesium, press, cobalt, copper) and a dispersed
ceramics (oxides, carbides) or metallic (lead, tungsten,
molybdenum) stage.
Metal Matrix Composites have many favorable circumstances
over solid metals like higher strength, higher specific modulus
and better properties at higher temperatures, and at bring low
thermal expansion coefficient.
 Prof. D. N. Rao

MMC Manufacturing Procedure:-

MMC manufacturing can be broken into three types

Solid State Methods

Liquid State Methods
Semi-solid State Method
Vapor State Method
 Prof. D. N. Rao

Solid State Method:-

Powder Metallurgy
Foil Diffusion Bonding
 Prof. D. N. Rao

Powder Metallurgy:-

Powder blending and consolidation (powder metallurgy): Powdered metal and

discontinuous reinforcement are mixed and then bonded through a process of
compaction, degassing, and thermo-mechanical treatment (possibly via hot
isostatic pressing (HIP) or extrusion).
 Prof. D. N. Rao

Powder Metallurgy:-
 Prof. D. N. Rao

Foil Diffusion Bonding:-

Layers of metal foil are sandwiched with long fibers, and then
pressed through to form a matrix.
 Prof. D. N. Rao

Liquid State Methods:-

Electroplating And Electroforming
Stir Casting
Pressure Infiltration
Squeeze Casting
Spray deposition
Reactive processing
 Prof. D. N. Rao

Electroplating and Electroforming:-

A solution containing metal ions loaded with reinforcing particles is
co-deposited forming a composite material.
 Prof. D. N. Rao

Stir Casting:-
Discontinuous reinforcement is stirred into molten metal, which is
allowed to solidify.

Video
 Prof. D. N. Rao

Pressure Infiltration:-
Molten metal is infiltrated into the reinforcement through use a kind of
pressure such as gas pressure.
 Prof. D. N. Rao

Squeeze Casting:-

Molten metal is injected into a form with fibers pre-placed inside it.
 Prof. D. N. Rao

Spray Deposition:-
Molten metal is sprayed onto a continuous fiber substrate
 Prof. D. N. Rao

Reactive Processing:-

A chemical reaction occurs, with one of the reactants forming the

matrix and the other the reinforcement.
 Prof. D. N. Rao

Semi Solid State Method:-

Semi-solid powder processing: Powder mixture is heated up to semi-
solid state and pressure is applied to form the composites.
 Prof. D. N. Rao

Vapor Deposition Method:-

Physical vapor deposition: The fiber is passed through a thick cloud
of vaporized metal, coating it.
 Prof. D. N. Rao

In-situ Fabrication Technique:-

Controlled unidirectional solidification of a eutectic alloy can result in
a two-phase microstructure with one of the phases, present in lamellar
or fiber form, distributed in the matrix.
 Prof. D. N. Rao

Ceramic Matrix Composite:-

Ceramic Matrix Composites are made out of a clay lattice and

strengthened with short fibers, or bristles, for example, those
produced using silicon carbide and boron nitride.
Ceramic fibers, for example, alumina and SiC (Silicon Carbide) are
worthwhile in high temperature applications, and furthermore where
there is a danger of condition assault.
 Prof. D. N. Rao

CMC Manufacturing Procedure:-

The manufacturing process consist of three different steps

Step 1:- Lay-up and fixation of the fibres, shaped as the desired
component.
Step 2:- Infiltration of the matrix material.
Step 3:- Final machining and, if required, further treatments
like coating or impregnation of the intrinsic porosity.
 Prof. D. N. Rao

Step 2:-
Infiltration Of The Matrix Material:-
The second step is done with five procedures
Deposition out of a gas mixture
Pyrolysis of a pre-ceramic polymer
Chemical reaction of elements
Sintering at a relatively low temperature in the range 10001200 C
Electrophoretic deposition of a ceramic powder
 Prof. D. N. Rao

Deposition out of A Gas Mixture:-

Chemical vapor deposition (CVD) is well suited for this purpose. In the presence of
a fibre, CVD takes place in between the fibres and their individual filaments and
therefore is called chemical vapor infiltration (CVI).
 Prof. D. N. Rao

Pyrolysis of A Pre-ceramic Polymer:-

Polymer Infiltration and Pyrolysis is the method of fabrication of

Ceramic Matrix Composites comprising an infiltration of a low
viscosity polymer into the reinforcing ceramic structure (e.g. fabric)
followed by pyrolysis: heating the polymer precursor in the absence
of oxygen when it decomposes and converts into a ceramic.
Prof. D. N. Rao
 Prof. D. N. Rao

Chemical Reaction of Elements:-

Some conventional ceramics are also manufactured by chemical

reactions.
For example, reaction-bonded silicon nitride (RBSN) is produced
through the reaction of silicon powder with nitrogen, and porous
carbon reacts with silicon to form reaction bonded silicon carbide, a
silicon carbide which contains inclusions of a silicon phase.
 Prof. D. N. Rao

Matrix Forming via Sintering:-

Sintering is the process of compacting and forming a solid mass of material
by heat or pressure without melting it to the point of liquefaction.
The general procedure of creating ceramic objects via sintering of powders
includes
Mixing water, binder, deflocculant, and unfired ceramic powder to form a
slurry;
Spray-drying the slurry
Putting the spray dried powder into a mould and pressing it to form a green
body (an uninterred ceramic item)
Heating the green body at low temperature to burn off the binder;
Sintering at a high temperature to fuse the ceramic particles together.
 Prof. D. N. Rao

Sintering Process:-
 Prof. D. N. Rao

Matrix Formed via Electrophoresis:-

In the electrophoretic process, electrically charged particles

dispersed in a special liquid are transported through an electric
field into the preform, which has the opposite electrical charge
polarity.
This process is under development, and is not yet used
industrially. Some remaining porosity must be expected here, too.
 Prof. D. N. Rao

Electrophoresis Process:-
 Prof. D. N. Rao

Polymer Matrix Composite (PMC):-

Polymer Matrix Composites are composed of matrix from

thermosetting (Unsaturated polyester (UP), Epoxy) or thermoplastic
(PVC, Nylon, Polystyrene) and embedded glass, carbon, steel or
Kevlar fiber (scattered stage).
Most usually utilized lattice materials are polymeric. Handling of
polymer framework composites require not include high weight and
doesn't require high temperature. Likewise equipment required for
assembling polymer grid composites are easier.
 Prof. D. N. Rao

Types of Polymer Matrix Composite:-

Fiber Reinforced Composites
In fiber reinforced composites, Fibre-reinforced plastic (FRP) is a composite
material made of a polymer matrix reinforced with fibres. The fibres are usually
glass, carbon, aramid, or basalt. Rarely, other fibres such as paper or wood or
asbestos have been used.
Particulate Reinforced Composites
In particle, reinforced polymer composites the polymer matrix reinforced with the
particulates. The particulates are usually silica, red mud, Al2o3, Sic etc. particle
reinforcing in composites is a less effective means strengthening than fiber
reinforcement.
 Prof. D. N. Rao

PMC Manufacturing Procedure:-

Open Mold Processes:- some of the original FRP manual procedures
for laying resins and fibers onto forms
Closed Mold Processes:- much the same as those used in plastic
molding
Pultrusion Processes:- similar to extrusion only adapted to include
continuous fiber reinforcement
 Prof. D. N. Rao

Open Mold Processes:-

Hand Layup Process

Spray Layup Process
Filament Winding
 Prof. D. N. Rao

Hand Layup Process:-

Oldest and most commonly used manufacturing method
Hand lay-up is the simplest composites molding method, offering
low cost tooling, simple processing, and a wide range of part sizes.
Design changes are readily made.

Video
 Prof. D. N. Rao

Spray Layup Process:-

Spray layup is also one of the hand mounding technique which is actually
extension of hand layup method.
In the spray-up process, the operator controls thickness and consistency, therefore
the process is more operator dependent than hand lay-up.
This process uses simple, low cost tooling and simple processing.
 Prof. D. N. Rao

Filament Winding:-
A continuous reinforcement, either previously impregnated or impregnated during
winding is wound around a rotating mandrel to form a composite part.
 Prof. D. N. Rao

Closed Mold Process:-

Vacuum Bag Molding

Vacuum Infusion
Resin Transfer Method
Compression Molding
Injection Molding
 Prof. D. N. Rao

Vacuum Bag Molding:-

Vacuum bag moulding is a modification of hand lay-up, in which the lay-up
(necessarily smaller) is completed and placed inside a bag made of flexible film
and all edges are sealed.
The bag is then evacuated, so that the pressure eliminates voids in the laminate,
forcing excess air and resin from the mould.
 Prof. D. N. Rao

Vacuum Infusion:-
Vacuum infusion can produce laminates with a uniform degree of
consolidation, producing high strength, lightweight structures. This
process uses the same low-cost tooling as open molding and requires
minimal equipment. Vacuum infusion offers substantial emissions
reduction compared to either open molding or wet lay-up vacuum
bagging.
 Prof. D. N. Rao

Resin Transfer Method:-

Resin transfer molding is a manufacturing method that is quite similar
to injection molding where plastic is injected into a closed mold

Video
 Prof. D. N. Rao

Compression Molding:-
Compression moulding process is followed by two step first one preheating and
pressurizing.
Good surface finishes are obtainable, contributing to lower part finishing cost.
Subsequent trimming and machining operations are minimized in compression
molding and labor costs are low.
 Prof. D. N. Rao

Injection Molding:-
It is a manufacturing technique for making parts from thermoplastic and
thermoset materials.
 Prof. D. N. Rao

Pultrusion:-
Pultrusion involves pulling resin-impregnated glass strands through a die.
 Prof. D. N. Rao

Particulate Reinforced Composite:-

This class of composites is most widely used composites mainly because they are
widely available and cheap.
Examples of particulate reinforced composites are layered silicate clay, Al2O3 etc..
 Prof. D. N. Rao

Layered Silicate Composites:-

In this study, the results of an experimental study based on the engineering
properties of clay samples collected from both the banks of river Nagavali
flowing through Srikakulam, India. 5 samples are collected from each bank at an
interval of 200cm and each at a depth of 100cm
The Nagavali clay as a matrix material and epoxy resin is reinforcement contained
within the matrix material. After purification of nagavali clay, the clay samples are
identified as layered silicat clay (Montmorillonite clay).
 Prof. D. N. Rao

Purification of Natural Clay:-

 Prof. D. N. Rao

Preparation Of Layered
Silicate Composite:-
 Prof. D. N. Rao

Application of Layered Silicate Composite:-

Grinding Wheel
 Prof. D. N. Rao

Patent Of Grinding Wheel:-

Patent with Title: COMPOSITE MATERIALS FROM LAYERED SILICATE CLAY

AND METHOD OF MAKING GRINDING WHEELS USING THE SAME,
APPLICATION NUMBER 742/KOL/2015, PUBLICATION DATE (U/S 11A) 07/08/2015,
DATE OF FILING 08/07/2015, Inventers:- Mr. A. Lakshumu Naidu, Dr. D.
NageswaraRao.
Prof. D. N. Rao