General Definitions

Composite: A composite (or composite material) is defined as a material that consists of at least two constituents (distinct phases or combinations of phases) which are bonded together along the interface in the composite, each of which originates from a separate ingredient material which pre-exists the composite. The essential elements of this definition are : i. composite refers to a material, as opposed to a structure or a component; as such a composite material is used for the fabrication of components of various shapes or functions, thus it should be distinguished from a wing or other structure made of several components bonded together, and from an electronic device or packaging structure made of layered materials (although one of the materials in the packaging could be considered a composite); ii. the composite is produced via a physical combination of at least two preexisting ingredient materials; this distinguishes a composite from other multiphase materials which are produced by bulk processes where one or more phases result from phase transformation: many "in-situ composites", such as directionally solidified eutectics or alloys from which a ceramic phase is precipitated, are thus considered to be alloys and not composites (even though their properties can be described using composite theory). Hybrid composite: a composite that consists of at least three (as opposed to two) constituents (distinct phases or combinations of phases) which are bonded together at the atomic level in the composite, each of which originates from a separate ingredient material which pre-exists the composite (i.e., there are, at least three ingredient materials). Ingredient materials: Raw materials put together to produce the composite (e.g., the metal alloy, metal powder, ceramic particles, etc.). During the processing the ingredient materials are transformed into the constituents of the MMC. Interface: that portion of the composite microstructure that lies between its constituents, i.e. matrix and reinforcement. The interface may be a simple row of atomic bonds (e.g., the interface between alumina and pure aluminium), but may also include matrix/reinforcement reaction products (e.g., aluminium

carbide between aluminium and carbon fibres), or reinforcement coatings (e.g., interfacial coatings between SiC monofilaments and titanium matrices). Metal matrix: the percolating metal or alloy forming the constituent of a MMC in which the other constituents are embedded. Metal Matrix Composite (MMC): a composite material in which one constituent is a metal or alloy forming at least one percolating network. The other constituent is embedded in this metal matrix and usually serves as reinforcement. Reinforcement: a constituent (phase or combination of phases) of the MMC originating from the ingredient material which is combined with a metal or an alloy to produce a metal matrix composite (e.g., alumina fibres, silicon carbide whiskers, steel fibres, or graphite particles, even if, in the case of graphite particles, the reinforcement does not "reinforce" the matrix). A reinforcement is characterised by its chemical composition, its shape and dimensions, its properties as ingredient material and its volume fraction and spatial distribution in the matrix. ... 2007-06-

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Reinforcement
Continuous fibres (f):cylindrical ingredient material produced continuouslyto form an essentially endless reinforcement in the composite; usually delivered on bobbins of multifilament tows, each tow consisting of many individual fibres of diameters typically in the range of 3 to 30 m. According to the production process such fibres are usually coated by a polymeric sizing and the tows may be slightly twisted. They are typically designated by a brand name, the number of fibres per tow and a symbol of the applied sizing (e.g. T300-6KE). Continuous reinforcement: a constituent of a composite which is continuous in at least one direction through the composite (e.g., continuous fibres or percolating open-celled foam). Discontinuous reinforcement:a non-percolating constituent of a composite, taking the form of individual elements embedded in the matrix constituent (e.g., particulates, short fibres, whiskers). Preforms produced from discontinuous reinforcements that are mechanically stabilised by a binder or by cold compaction are still considered discontinuous reinforcements. Dispersoids (d): same as particulates, except that the diameter is less than 1m, hence, being capable of providing Orowan strengthening.

Monofilaments (m): essentially endless reinforcement as continuous fibres, except for a larger diameter, typically greater than 100 m. Monofilaments are generally produced by deposition onto a core fibre (most often of carbon or tungsten), and are delivered as individual fibres instead of tows. Particulates (p): roughly equiaxed reinforcement or composite ingredient, usually of aspect ratio (ratio of largest to smallest diameter) less than about 5. Particulates can be both monoor polycrystalline, can take various shapes (spherical, angular, plate-like) and are typically greater than 1 m in diameter. Platelets: flat reinforcements of an aspect ratio (diameter to thickness) greater than 2. Platelets of an aspect ratio less than 5 can be considered as a type of particulates. Short fibres (s): cylindrical reinforcement or composite ingredient with a ratio of length to diameter greater than 5 (but typically greater than 100), and with a diameter typically greater than 1 m. Whiskers (w): elongated single crystals, typically produced with a length to diameter ratio greater than 10 and with a diameter typically less than 1m.

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Categories of MMC
Cellular metals (metal foams): similar to MMC as they are often formed by combining two separate ingredients yielding a metal matrix and the second constituent being the gas in closed or open pores: however, there is no clear bond between the gas phase and the matrix. Cermets: a metal matrix composite with a three-dimensionally percolating ceramic reinforcement, typically with far more ceramic than metal (generally containing less than 20% metal by volume). According to the percolating structure of both constituents cermets can thus be considered as both a ceramic and a metal matrix composite. Continuous fibre reinforced MMC (CFRM): metal matrix composite with reinforcement of continuous fibres.

Dispersoid reinforced MMC: metal matrix composite with a dispersoid reinforcement occupying a volume fraction greater than 5% in the material (otherwise, the material is considered to be a dispersion strengthened metal which incidentally may form the matrix of any type of MMC, i.e., a MMC with dispersion-strengthened matrix). MMC designation: method of indicating the composition and at times also the processing of the MMC. As proposed by the American Aluminum Association for the designation of aluminium composites, MMC should be designated as follows by their constituents: accepted designation of the matrix / abbreviation of the reinforcements designation / arrangement and volume fraction in % with symbol of type (shape) of reinforcement. Some examples are: matrix of a magnesium alloy AM10 reinforced by continuous carbon fibres of type T300, unidirectionally oriented, amounting to a volume fraction of 65% is designated as "AM10/C-T300/UD65 f"; or matrix of the aluminium alloy AA6061 reinforced by particulates of alumina of 22 % by volume is designated as "AA6061/Al2O3/22 p". MMC product names used by companies vary, hence their use indicates the processing route employed by implicit reference to the producer. Monofilament reinforced MMC (MFRM): metal matrix composite with reinforcement of monofilaments.

Particulate reinforced MMC(PRM): metal matrix composite with a particulate reinforcement occupying a volume fraction greater than 5% in the material (otherwise, the particulates are generally considered to be inclusions).

Short fibre reinforced MMC(SFRM): metal matrix composite with a short fibre reinforcement.

Whisker reinforced MMC (WRM): metal matrix composite with a whisker reinforcement.

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Processing Steps
Pre-processing: all steps which precede primary processing (e.g., surface treatment of ingredient materials, or preform fabrication for infiltration processing). Preform: a shaped porous assembly of ingredient material elements (such as fibres, whiskers or particles). Typically, preforms are produced for subsequent infiltration with liquid metal, or foil-fibre-foil stacks prior to diffusion bonding. The mechanical stability of the shape may be provided by the adjunction of a binder, potentially but not always fugitive, and amounting to only a few mass % of the preform. Hybrid preform: a preform containing a t least two types of ingredient material elements which form at least two distinct reinforcing constituents in the composite (e.g. particulate-fibre mixtures, hollow micro-spheres). Primary processing of composites: production of composite material by combining ingredient materials (e.g., powdered metal and loose ceramic particles, or molten metal and fibre preforms), but not necessarily to final shape or final microstructure. Continuous MMC primary process: a process for the production of MMC material that is essentially continuous (e.g., foil-fibre-foil diffusion bonding using a rolling mill, or continuous infiltration).

Secondary processing: processing steps which follow primary processing, and aim to alter the shape or microstructure of the material ( e.g., shape casting, forging, extrusion, heat-treatment, machining). Secondary processing may change the constituents (phases, shape) of the composite. Consolidation of MMC: a secondary composite manufacturing process during which composite elements are consolidated (e.g., the consolidation of composite elements consisting of the reinforcement coated with the matrix metal). MMC insertion casting: a secondary process for production of partially reinforced components, in which a pre-fabricated MMC is placed within a mould, and incorporated into a metal or alloy by a casting process. Partially reinforced metal component: semi-products or components which contain MMC material metallurgically bonded to a conventional metal or alloy (e.g. by diffusion bonding, insertion casting, co-extrusion). In-situ MMC: a MMC in which the ingredient reinforcement material changes its phase or shape during primary composite processing (e.g. TiB2 reacts to form TiC in some metals by adding carbon). To be an MMC, the constituents must, however, retain its local identity, although they change in shape and/or composition (otherwise, it is an alloy).

Liquid Metal Processing

Stir casting: a primary process of composite production whereby the reinforcement ingredient material is incorporated into the molten metal by stirring. Compocasting: a variant of stir-casting in which the metal is semi-solid, i.e. a rheocasting process incorporating the reinforcing ingredient material to form the composite. (The semisolid state aids incorporation of the particles, in particular because the metal is more viscous.) Semi-solid forming: a family of secondary forming processes which use semi-solid alloy or metal matrix in the case of a MMC. Thixocasting: a family of secondary casting or forming processes, which shape partially remelted thixotropic (semi-solid) metallic materials by deformation.

Infiltration: a primary process of composite production whereby the molten metal is made to fill, spontaneously or using external mechanical work, pores within a preform of the reinforcement ingredient. Spontaneous infiltration: an infiltration process in which the matrix penetrates spontaneously the preform without added force (e.g., copper into tungsten because of direct wetting, or by coating nickel onto the reinforcement for infiltration with aluminium, or by control of the atmosphere and the alloy composition as in the Lanxide- Primex process). Forced infiltration: an infiltration process which is not spontaneous, i.e., which requires application of mechanical force onto matrix or reinforcement. Pressure infiltration: an infiltration process in which hydrostatic pressure is applied onto the molten matrix surface to drive the liquid into the preform. Vacuum infiltration: an infiltration process in which a hydrostatic pressure of one bar applied by the atmosphere onto the molten matrix drives it into an evacuated preform. In some processes the vacuum can be selfgenerated, for example by reaction of magnesium with air or oxygen in the preform. Gas pressure infiltration: a pressure infiltration process which uses pressurized gas to apply pressure on the metal surface driving the liquid into a preform. Pressure assisted investment casting: an investment casting process where a preform is integrated into the pattern and the assembly is cast while the mould and the melt are under hydrostatic gas pressure. Mechanical pressure infiltration: a pressure infiltration process which uses a moving solid part to apply pressure on the melt surface driving the liquid into a preform. Squeeze casting infiltration: a mechanical pressure infiltration process in which a preform is placed into a solid mould, and pressure infiltration is affected with a moving solid piston providing laminar flow of the molten matrix into the mould. Variants include direct squeeze casting, in which the piston surface represents a fraction of the final casting surface; and

indirect squeeze casting, in which the piston acts on the ingate to the die. Pressure die infiltration: an infiltration process which uses a pressure die casting apparatus, in which a preform is placed into a solid mould, and pressure infiltration is effected with a moving solid piston causing turbulent flow of the melt upstream of the preform. Centrifugal infiltration: an infiltration process in which centrifugal force is used to drive the molten matrix into the preform. Ultrasonic infiltration: an infiltration process in which ultrasonic pressure waves are used to drive the molten matrix into the preform. Lorentz force infiltration

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Solid State Processing

MMC diffusion bonding: a primary process for composite fabrication in the solid state, in which stacks of matrix metal and reinforcement ingredients (usually parallel fibre onolayers and matrix foils, see also fibre winding) are encapsulated and bonded together after vacuation by mechanical pressure at elevated temperature to enhance diffusion. Foil-fibre-foil method (also called foil-fibre method): a primary composite production process wherein layers of metal foil and ceramic monofilament fibres are alternatively stacked to produce precursor materials for subsequent diffusion bonding, specifically hot pressing. Wire winding: a method for production of precursor MFRM material produced by co-winding metal wires and ceramic fibres for subsequent diffusion bonding, specifically hot pressing Powder cloth method: variant of the foil-fibre-foil method for production of MFRM, in which matrix metal powders and a binder are mixed and formed into a cloth or foil before stacking.

Powder consolidation: a diffusion bonding (primary) process in which matrix in powder form is blended or otherwise placed next to the reinforcing ingredient material, and consolidated with or without pressure and elevated temperature. MMC sintering: consolidation of ingredient materials at elevated temperatures without application of pressure. MMC liquid phase sintering: consolidation of ingredient materials comprising the presence of a liquid phase (at least temporarily) in the compact. MMC hot pressing: consolidation of ingredient materials by diffusion bonding with application of pressure by means of a piston (a hot press) at temperatures high enough to effect concurrent sintering of the matrix, which for metal matrices is generally above the matrix recrystallisation temperature. MMC cold pressing: consolidation of ingredient materials with application of pressure by means of a piston, at temperatures too low to effect concurrent sintering of the matrix, which for metal matrices is generally below the matrix recrystallisation temperature. MMC hot isostatic pressing (HIP): diffusion bonding of ingredient materials with application of hydrostatic pressure by means of a gas, at temperatures high enough to effect concurrent sintering of the matrix, which for metal matrices is generally above the matrix recrystallisation temperature. MMC cold isostatic pressing (CIP): cold pressing of ingredient materials with application of hydrostatic pressure by means of a fluid (or gas), at temperatures too low to effect concurrent sintering of the matrix, which for metal matrices is generally below the matrix recrystallisation temperature. MMC powder rolling: consolidation of ingredient materials with application of pressure by means of a rolling mill. Cold rolling occurs below the recrystallisation temperature of the metal, hot rolling at higher temperatures. MMC powder extrusion: consolidation of ingredient materials with application of pressure by means of an extrusion press. Cold extrusion occurs below the recrystallisation temperature of the metal, hot extrusion at higher temperatures.

MMC powder forging: consolidation of ingredient materials with application of pressure by means of a forging press. Cold forging occurs below the recrystallisation temperature of the metal, hot forging at higher temperatures.

Coating Processes
Coating processes: primary processes which coat the matrix onto individual reinforcement elements of the ingredient material (e.g., vapour deposition, or electrolytic coating) creating composite elements, which generally require subsequent consolidation. Vapour deposition coating (in the context of composite production): primary process wherein the matrix is deposited from the vapour phase onto individual reinforcement elements of the ingredient. Electrolytic coating (in the context of composite production): primary process wherein the matrix is deposited from solution using electrochemical means onto individual reinforcement elements of the ingredient material. Matrix coated fibre method: a family of primary coating process whereby continuous or monofilament fibres are coated with metal matrix material by physical vapour deposition, or by sputtering techniques or by chemical means prior to composite consolidation. Vapour infiltration: a primary process wherein the matrix is deposited from the vapour phase into the pores of a preform of reinforcement material. Electrolytic infiltration: a primary process wherein the matrix is deposited from solution using electrochemical means into the pores of a preform of reinforcement material. Electrolytic co-deposition: a primary composite processing method which consists in electrolytic deposition of the matrix metal from a solution containing the reinforcement ingredient, so as to trap the reinforcement within the deposited metal layer. Plasma spray method: variant of the foil-fibre-foil method where monolayers of monofilament fibres or continuous fibre tows are plasma sprayed with the

matrix metal and subsequently stacked and diffusion bonded, specifically hot pressed. Slurry tape casting: method where monofilament fibres are coated with a slurry of matrix metal powder thus forming a tape that can be stacked and diffusion bonded, specifically hot pressed, to form MFRM.

Role within the Production Chain

Supplier: industrial or research institution that markets and sells MMC or MMC ingredient materials, or products thereof. Producer: industrial or research institution that produces MMC or MMC ingredient materials, or products thereof. Ingredient material supplier or producer: supplier or producer of ingredient materials that are used to make a composite (includes fibre or ceramic particle producers, as well as perform producers). MMC supplier or producer: supplier or producer of metal matrix composite materials. MMC producer performs at least primary processing of the material. MMC component supplier or producer: supplier or producer of metal matrix composite material components produced to final shape and microstructure MMC component producer performs at least a secondary processing step of the material). MMC end-user: the producer of an end-product which incorporates metal matrix composite materials (e.g., a bicycle manufacturer) MMC consumer: the user of an end-product which incorporates metal matrix composite materials (e.g., the cyclist with reference to a bicycle).