Chapter 1

INTRODUCTION
Metal matrix composites (MMCs), like all composites, consist of at least two
chemically and physically distinct phases, suitably distributed to provide
properties not obtainable with either of the individual phases. Generally,there are
two phases, e.g., a fibrous or particulate phase, distributed in a metallic matrix.
Examples include continuous A1203 fiber reinforced A1 matrix composites used
in power transmission lines; Nb-Ti filaments in a copper matrix for
superconducting magnets; tungsten carbide (WC)/cobalt(Co) particulate
composites used as cutting tool and oil drilling inserts; and Sic particle reinforced.

Advantages
With respect to PMCs, MMCs offer these distinct advantages:

Higher strength and stiffness

Higher service temperatures
Higher electrical conductivity (grounding, space charging)
Higher thermal conductivity
Better transverse properties
Improved joining characteristics
Radiation survivability (laser, UV, nuclear, etc.)
Little or no contamination

TYPES OF MMCs
All metal matrix composites have a metal or a metallic alloy as the matrix.The
reinforcement can be metallic or ceramic. In some unusual cases, the composite
may consist of a metallic alloy "reinforced" by a fiber reinforced polymer matrix
composite (e.g., a sheet of glass fiber reinforced epoxy or aramid fiber reinforced
epoxy).
In general, there are three kinds of metal matrix composites (MMCs):
(i) particle reinforced MMCs
(ii) short fiber or whisker reinforced MMCs
(iii) continuous fiber or sheet reinforced MMCs

Table #1. Type of reinforcements with Aspect ratios, particle Diameter

Purpose of Reinforcement in MMCs:

Reinforcements for metal matrix composites have a manifold demand profile, which
is determined by production and processing and by the matrix system of the
composite material. The following demands are generally applicable
low density
mechanical compatibility
chemical compatibility
thermal stability
high Youngs modulus
Following is the pictorial depiction of specific tensile strength and specific
Youngs modulus of different quasi-isotropic fiber composite materials in
comparison to some metal alloys;

Fig#1. Specific Tensile

Strength vs Specific Youngs
Modulus

Aluminium based MMCs:

low density and excellent strength, toughness and resistance to corrosion,

Important applications in the aerospace field.

AlCuMg and AlZnMgCu alloys, very important precipitation-hardenable

alloys. Aluminum-lithium alloys

Lithium, when added to aluminum as a primary alloying element, has the

unique characteristic of increasing the elastic modulus and decreasing the
density of the alloy.

AlLi alloys are precipitation hardenable, much like the AlCuMg and AlZn
MgCu alloys.

Titanium alloys:

It has a density of 4.5 g/cm3 and a Youngs modulus of 115 GPa.

For titanium alloys, the density can vary between 4.3 and 5.1 g/cm3, while
the modulus can have a range of 80130 GPa.

High strength/weight and modulus/weight ratios are important.

Titanium has a relatively high melting point (1,672C) and retains strength to
high temperatures with good oxidation and corrosion resistance.

All these factors make it an ideal material for aerospace applications.

Titanium alloys are used in jet engines (turbine and compressor blades),
fuselage parts, etc. It is, however, an expensive material.

Processing of MMCs :
Liquid State Processing

Casting, or liquid infiltration, involves infiltration of a fiber bundle by liquid

metal.

It is not easy to make MMCs by simple liquid-phase infiltration, mainly

because of difficulties with wetting of ceramic reinforcement by the molten
metal

Duralcan process.

Ceramic particles and ingot-grade aluminum are mixed and melted.

The ceramic particles are given a proprietary treatment.

The melt is stirred just above the liquid, temperature generally between 600
and 700 oC.

It involves the use of 812 mm particles

Fig. #3 Duralcan process

MMCs: Centrifugal Casting

One of the disadvantages of MMCs with ceramic reinforcement is that they are
typically more difficult to machine than the unreinforced alloy. In centrifugal
casting, optimal placement of the reinforcement can be achieved by inducing a
centrifugal force immediately during casting which allows one to intentionally
obtain a gradient in reinforcement volume fraction.For Example in casting of
brake rotor of WC/Bronze composite centrifugal casting is utilized to prevent
accumulation of particles near the hub area for easier machining
MMCs: Powder and Spray Processing
WC and Co particles are blended in the organic liquid binder.Compacted and
Sintered as liquid phase sintering.This is done where the contact angle of wetting of
two materials is low like here its zero.

Fig.# 4 Schematic of Spray

Processing

Porous preform is obtained which could be wrought or sintered in spray

processing.

Applications:
Metal matrix composites are used in a myriad of applications. The high
strength-to-weight ratio, enhanced mechanical and thermal properties over
conventional materials, and tailorability of properties make them very
attractive in a variety of applications. Increasingly MMCs have been used in
several areas including:
Aerospace
Transportation (automotive and railway)
Electronics and thermal management
Filamentary superconducting magnets
Power conduction
Recretational Products and Sporting Goods
Wear-resistant materials

Issues of MMCs :
Describes the phenomenon of permeability of porous medium by a fluid.
Specifically, in the case of MMCs, we can write for the permeability of a
porous medium, k, in terms of Darcys Law for single-phase fluid flow:

Where J is volume current density (i.e., volume/area time) of the fluid, is the
fluid viscosity, and P is the pressure gradient responsible for the fluid flow.
Other Issues
Molten aluminum and silicon carbide can react and form Al 4C3.Aluminum alloys
that minimize reactivity with SiC should be used.AlSi alloys (with Si levels of up
to 9%) are typically used with SiC reinforcement. With increasing temperature,
an increase in the amount of silicon is required to prevent Al4C3 formation.
Covering the melt with an inert gas atmosphere will reduce oxidation of the melt.
Addition of reinforcement particles increases the viscosity of the melt. Several
equations have been proposed for the viscosity, c of particulate composite. The
Einstein equation for dilute suspensions of spherical particles is well known, but
it is valid for particle concentrations less than 0.1.