Vamsi krishna mamidi, M.

Anthony Xavior

A REVIEW ON AL-SIC PMMC COMPOSITE

In the materials R&D has shifted from monolithic to

composite materials, adjusting to the global need for reduced Weight,
low cost, quality, and high performance in structural materials. The
developments in the molten processing of particulate Al-Si alloy
composites and their respective properties. Existing and emerging
processing innovations are discussed, and the reinforcement phases
in prominent R&D activities are identified. The vortex (or mixing)
method continues to be the most popular processing method in use
because of its ease of operation, total production cost, and suitability,
while the infiltration, compo casting (or recasting), in-situ and spray
atomization and co- deposition techniques receive less attention.
Machining of composite materials is difficult to carry out
due to the anisotropic and homogenous structure of composites and to
the high abrasiveness of their reinforcing constituents. This typically
results in damage being introduced into the work piece and in very
rapid wear development in the cutting tool. Conventional machining
processes such as turning, drilling and milling can be applied to
composite materials, provided proper tool design and operating
conditions are adopted. An overview of the various issues involved in
the processing and machining of the AlSIC PMMC composite
materials is presented in this paper.

Keywords particulate metal matrix

composite material processing, composite machinig

composite,

1.INTRODUCTION
Materials design has shifted emphasis to pursue
light weight, environment friendliness, low cost, quality, and
performance. Parallel to this trend, metal-matrix composites
(MMCs) have been attracting growing interest. Manoj
singla[1] Metal matrix composite (MMC) is engineered
combination
of the
metal
(Matrix)
and
hard
particle/ceramic(Reinforcement)
to
get
tailored
properties.MMCs are either in use or Prototyping for the
space shuttle, commercial airliners, electronic substrates,
bicycles, Automobiles, golf clubs, and a variety of other
applications. MMCs attributes include alterations in
mechanical behavior (e.g., tensile and compressive properties,
creep, notch
resistance, and tribology) and physical
properties (e.g., intermediate density, thermal expansion, and
thermal diffusivity) by the filler phase; the materials
limitations are thermal fatigue, thermo chemical
compatibility, and low transverse creep resistance. Metal
matrix composites possess sets of proper ties that are of
interest to designers for both structural and non-structural
applications. These include specific stiffness, specific
strength, fatigue resistance, wear resistance, and coefficient of
thermal expansion (CTE).
In AlSiC the key material of commercial importance
has been coined AlSiC by the industry. While not
representing any specific formulation, in general AlSiC
covers particle-reinforced aluminum MMCs in which the SiC

Vamsi krishna mamidi is a Assistant Professor, MITS, madanapalle, 517325,

India.(email: mamidivk@gmail.com).
Dr. Anthony Xavior M is an Associate Professor and Programme Manager
with the School Of Mechanical and Building Sciences, VIT University, Vellore632 014, India. (Email: manthonyxavior@vit.ac.in).

volume fraction ranges from 20% to over 70% by volume, de

pending on the specific needs of the application.
There is a broad family of materials in this category aimed at
achieving an enhanced combination of properties and this
can be attained by selecting different matrices as well as
reinforcing phases. In addition to the matrix microstructure,
reinforcing phase also controls the characteristics attainable
by the MMCs Matrices reinforced with high modules short
fibres,whiskers or particulates have improved strength
and stiffness and are isotropic in nature. This variety of
the composites is less expensive to produce. In the case of
continuous fibre or whiskers with high aspect ratio [length
/diameter], to align fibers in the desired stress direction and
to transfer the applied load to the fibers the matrix serves
to hold them together. The mechanical properties of the
composites are dependent upon the efficiency of the matrix
in transferring the load to the reinforcement fibres and are
therefore
related to the quality of
the fibre/matrix
interfacial bonding (17). This type of composites exhibits
significantly higher strength and stiffness. But they are nonisotropic in nature and are expensive. Aluminum and its
alloys form the most widely investigated matrix for use in
MMCs.This popularityof Al-alloy as a matrix material can
be attributed to its low cost relative to other light
structural metals such as Mg,Ti,etc. its current dominance
on the aerospace structural application and so on. There
are two types of reinforced aluminum alloy composite:
1.Discontinuously [short fibre, whisker and particulate
reinforced] 2.Continuously reinforcement aluminum alloy
composites [long continuous fiber reinforced].
T.W.Clyne[2].Particulate MMC is being used or developed
for a range of industrial applications. While these are often
focused on Al alloy matrices, Ti-, Fe- and Mg-based systems
are also of interest. Particulate is most commonly SiC or
Al2O3, but others (TiB2 , B4C, SiO2 , TiC, WC, BN, ZrO2, W
etc) have been investigated.
Chemical reaction
during processing can occur in some cases. Silicon
carbide can be particularly problematic in Al- and Ti-based
MMCs. The reaction between SiC and Al melts has been
investigated in detail and SiC reacts with Ti even during solid
state consolidation. Alumina is less reactive than SiC in Al
alloys, but it does react quite strongly with Ti. Magnesium is
rather different from Al and Ti, in that it does not readily for
stable carbide. However its affinity for oxygen is very strong.
The greater stability of Al 2O3, compared with SiC in Al is
therefore reversed for Mg matrices In general, while coatings
or other surface treatments may be worth considering for
fibers (particularly monofilaments), economic and practical
considerations mean that
particulate reinforcement is
normally introduced into MMCs in the virgin state.
This may, however, be such that a surface oxide layer is
present and deliberate thickening of this layer, for example by
heat treatment in air, has in some instances been found to
have a beneficial effect on interfacial bonding or other
characteristics.
T.W.Clyne[2].Particulate MMCs are most commonly
manufactured either by melt incorporation and casting
technique or by powder blending and consolidation. Other

routes include reactive processing or spray co-deposition.

Quality control objectives include the elimination of excessive
interfacial reaction during processing, particularly for melt
routes, and also the avoidance of micro structural defects
such as poor interfacial bonding, internal voids and
clustering of the reinforcement.Typically, for structural
applications reinforcement particles are about 10-20 m in
diameter and constitute about 10-30% by volume of the
material, although MMCs in which the values concerned
lie outside of these ranges have been studied and are available
commercially (particularly finer particles and higher particle
contents).For electronic substrate applications, far higher
particle contents, around 70% by volume, are commonly
employed. These are obtained using multi-modal particle size
blends.
2.PROCESSING ALUMINIUM ALLOY COMPOSITE
Like all composites, aluminum-matrix composites
are not a single material but a family of materials
whose stiffness, strength, density, thermal and electrical
properties can be tailored. The matrix alloy, reinforcement
material, volume and shape of the reinforcement,
location of the reinforcement and fabrication method can
all be varied to achieve required properties. The aim involved
in designing metal matrix composite materials is to combine
the desirable attributes of metals and ceramics. The addition
of high strength, high modulus refractory particles to a
ductile metal
matrix
produce a material
whose
mechanical properties are intermediate between the matrix
alloy and the ceramic reinforcement. Metals have a useful
combination of properties such as high strength, ductility and
high temperature rsistance, but sometimes have low
stiffness, whereas ceramics are stiff and strong,though
brittle.Aluminum and silicon carbide, for example, have
very different mechanical properties: Young's moduli of 70
and 400 GPa, coefficients of thermal expansion of 24 10 -6
and 4 10-6/C, and yield strengths of 35 and 600 MPa,
respectively.
By
combining
these
materials,
e.g.A6061/SiC/17p (T6condition), MMC with a Young's
modulus of 96.6 GPa and a yield strength of 510 MPa can be
produceds. Skolianos[3 ].By carefully controlling the
relative amount and distribution of the ingredients of a
composite as well as the processing conditions, these
properties can be further improved. The correlation
between tensile strength and indentation behavior in particle
reinforced MMCs manufactured by powder metallurgy
technique Y.l.,shen [4]. The microstructure of SiC reinforced
aluminium alloys produced by molten metal method. It was
shown that stability of SiC in the variety of manufacturing
processes available for melt was found to be dependent on the
matrix alloy involved Llyod.D.J [5].
Among discontinuous metal matrix composites, stir
casting is generally accepted as a particularly promising route
currently practiced commercially. Its advantages lie in its
simplicity, flexibility and applicability to large quantity
production. It is also attractive because, in principle, it allows
a conventional metal processing route to be used, and hence
minimizes the final cost of the product. This liquid metallurgy
technique is the most economical of all the available routes
for metal matrix composite production M.K.Surappa [6], and
allows very large sized components to be fabricated. The cost
of preparing composites material using a casting method is

about one-third to half that of competitive methods,

and for high volume production, it is projected that the
cost will fall to one-tenth D.M.Skibo [7]. In general,the
solidification synthesis of metal matrix composites involves
producing a melt of the selected matrix material followed by
the introduction of a reinforcement material into the melt,
obtaining a suitable dispersion.
The next step is the solidification of the melt
containing suspended dispersoids under selected conditions to
obtain the desired distribution of the dispersed phase
in the cast matrix. In preparing metal matrix composites
by the stir casting method, there are several factors that need
considerable attention,
including
the difficulty
of
achieving
a uniform distribution of the reinforcement
material, wettability between the two main substances,
porosity in the cast metal matrix
composites,
and
chemical reactions between the reinforcement material
and the matrix alloy. In order to achieve the optimum
properties of the metal matrix composite, the distribution of
the reinforcement material in the matrix alloy must be
uniform, and the wettability or bonding between these
substances should be optimized. The literature review
reveals that the major problem was to get homogenous
dispersion of the ceramic particles by using low cost
conventional equipment for commercial applications. In the
present work, a modest attempt have been made to compare
the dispersion of SiC particles in Al matrix fabricated with
the help of different processes viz. (a) without applying
stirring process (b) with manual stirring process (c) a twostep mixing method of stir casting. An effort has
been
made
to
establish
a
relationship between
hardness, impact strength and weight fraction of SiC
in particle reinforced MMCs developed with the help of
two - step mixing method of stir casting technique.
Several investigators have reviewed the synthesis of
MMCs, J.U.Ejiofor [8],K.G.Satyanarayana[9], R.Kreibar[10]
and, especially AMCsK.KChawla[11]. P.K.Rohtagi[12],
K.G.Satayanarayana[9] .B.C.Pai[13]. Traditional molten
processing (MP) involves a variety of methods, including
mixing/vortex, infiltration, and recasting; some of these MP
routes are currently being extended to a secondary processing
stage such as extrusion. Methods other than the MP route
include P/M, spray atomization/co deposition (SD), and insitu production.
2.1.Mixing/Vortex
In the mixing/vortex method, the pretreated and
prepared filler phase is introduced in a continuously
stirred molten matrix and then cast. The use of an inert
atmosphere or vacuum other than air is essential to avoid the
entrapment of gases. Mixing can be affected ultrasonically or
by reciprocating rods, centrifuging, or zero-gravity processing
that utilizes an ultrahigh vacuum and high temperatures
for long periods of time. A method of inertial injection
has been developed for this process. Difficulties, such as the
segregation/settling of secondary phases in the matrix,
agglomeration of ceramic particulate, particulate fracture
during
agitation, and extensive interfacial reactions, are
often encountered. The DURAL process, which incorporates
SiC and Al 2o3 particles into molten aluminum, makes use of
this method.8
2.2.Infiltration

In infiltration, the molten metal penetrates a

pretreated, formed, and prepared particulate bed or performs
with pressure or without pressure (pressure less infiltration).
In the latter case, however, the molten alloy infiltrates the
reinforcement by percolation. This method is normally carried
out in air, inert gas, or evacuated atmosphere. Mortensen [14]
have associated this technique with such disadvantages as
reinforcement contact, structural distortion of the perform,
large grain size, and undesirable interfacial reactions that
culminate into micro structural in homogeneity.
The first commercial application was the fabrication of
aluminum-alloy diesel pistons containing alumina short fibers
by Toyota Motor Corporation.t.donomoto[15],Squeeze casting
was the primary manufacturing mode. Aluminum-alloy melt
was poured into a porous alumina short-fiber perform inserted
into a preheated die, and a squeeze pressure was applied in a
hydraulic press. The composite aluminum pistons possessed
better performance attributes than the unreinforced ones.
The Lanxide process, which is a melt
oxidation process, is another infiltration route in the synthesis
of (aluminum matrix composite) AMCs. In fact, Lanxide and
Alcan have jointly produced an Al 2O3 /Al alloy composite of
exceptional low erosive wear rate30 through this process. It
involves the infiltration of a final-product-shape ceramic
preform by a molten alloy. The preform is normally formed
by pressing, slip casting, joining, or injection molding. In air
or under a preferred gas, the molten alloy slips through the
preform and oxidizes or chemically reacts with the
preform material. The final composite phases consist of the
oxidation (or reaction) products and the remaining matrix
material. By this method, dense composite shape is usually
achieved.
2.3.Rheocasting
Rheocasting (or compo casting) permits the
introduction of the pretreated particulate or short fibers into
the solidifying, highly viscous, and thixotropic dendritic
slurry of the molten matrix by agitation. This mechanically
entraps the ceramic reinforcements and prevents any form of
segregation. Continued stirring then reduces the viscous mass
to low-viscous, fine, nondendritic slurry. This results in a
mutual interaction between the matrix melt and the filler
phase, which enhances wetting and bonding between the two
phases. Pressure is usually used to effect a sound casting,
E.F.Fascetta [16] especially when the volume fraction (Vf) of
the particulate material is greater than 0.3 or 0.15, in the case
of short fibers. This is because the composite viscosities
increase as Vf increases, which is limiting at lower volume
fractions. Fiber damage/degradation due to vigorous agitation
is another difficulty. Owing to these effects, rheocasting lends
itself only to particulate composites with a very low V of low
to medium density particulates. R.Mehrabian [17] A
fundamental characteristic of this technique is that the matrix
alloy isothermally held within the freezing range of the alloy
and, together with the reinforcement, is mechanically stirred.
Stirring and agitation help to break the solid phases into
smaller forms, releasing any particulate clusters that also
break down in the process. New particle-matrix bonding can
then take place, through which particulate agglomeration and
gravity-induced settling is eliminated.
2.4.Powder Metallurgy (P/M)
P/M is used in the synthesis of both AMCs and
ceramic-matrix composites through the relatively low cost

methods of single compaction, double compaction,and

mechanical deformation following hot pressing as well as
through high-cost hydrostatic and isostatic compaction, hot
dynamic compaction, or explosive compaction methods. P/M
involves the blending of well-characterized matrix powders
and discontinuous reinforcement, compaction at ambient or
hot conditions, degassing, and consolidation. In these solidstate techniques, subfusion temperature regimes are normally
attained in consolidation for optimum results. Depending on
the morphology of the reinforcement or the desirable
properties, further processing by mechanical-deformation
mechanisms is applied.
H.J.Rack [18] Alcoa, DWA Composite Specialties,
Ceracon, and the
Advanced
Composite
Materials
Corporation
are using this method in some of their
commercial operations. H.j.rack [19]Through the cold
compaction of a pretreated elemental matrix blend and
particulate mix followed by optimum consolidation conditions
by sintering, highly wear-resistant zircon/Al-Si composites
have been recently reported by Ejiofor et al. Another recent
study has also produced wear-resistant char/Al-Si-Mg
composites with 0.02 Vf via reaction sintering.Inal and
coworkers have used the explosive compaction to
fabricate SiC-reinforced 7093 AMCs.S.Krishna Murthy [20]
During explosive consolidation, a strong shock-hardening
behavior of the matrix alloy was found.
Similar to P/M is the solid-phase synthesis of particulate
AMCs by rapidly quenching the metal powders and fine
ceramic particulate using high (mechanical or electrical)
energy sources to consolidate the mixture in as short a time as
possible. It is a high-energy, high-rate process. The short time
at temperature benefits phase-transformation control and
reduces the chance of degeneration into coarse
microstructure. The P/M level halfway in the freezing range
during the application of pressure. A related (the meltoxidation process) has been used by Lanxide and Alcan30 in
producing Al2O3 /Al3 composites have low erosive wear
rates.
Chen and Chung have reported anew composite network
comprising interpenetrating networks of silicon process has
been successfully applied in the manufacture of both Al-SiC
and SiC/Ti3 Al + Nb composites.
2.5.Powder Blending and Consolidation
Blending of metallic powder with ceramic fibers or
particulate is a versatile technique for MMC production. This
is usually followed by cold compaction, canning, evacuation,
degassing and a high temperature consolidation stage such as
Hot Isostatic Pressing (HIP) or extrusion. Achieving a
homogeneous mixture can be difficult, particularly with
fibers. A feature of much powder route material is the
presence of fine oxide particles, usually present in Al-MMCs
in the form of plate-like particles a few tens of nm thick,
constituting about 0.05-0.5vol%, depending on powder
history and processing conditions. This fine oxide tends to act
as a dispersion strengthening agent and often has a strong
influence on the matrix properties, particularly at high
Temperature.
MMCs produced by powder blending are commonly
extruded. This can generate alignment of fibers parallel to the
extrusion axis, but often at the expense of progressive fiber
fragmentation .The degree of fiber fracture decreases with
increasing temperature and decreasing local strain rate.

Other micro structural features of extruded MMCs include the

formation of ceramic-enriched bands parallel to the extrusion
axis. The mechanism of band formation is still unclear, but it
appears to involve the concentration of shear strain in regions
where ceramic particles or fibers accumulate. However,
extrusion of consolidated MMCs, such as castings, can reduce
the level of clustering and in homogeneities in the material.
In general, the micro structural changes occurring in MMCs
during forming processes are explicable in terms of local
temperatures, stresses and strain rates. Processes such as
rolling and forging involve high deviatoric strains being
imposed quickly, and hence can cause damage such as
cavitation, particle fracture and macroscopic cracking,
particularly at low temperature. Very high temperatures, and
the possibility of matrix liquation, on the other hand, can
cause macroscopic defects such as hot tearing or hot
shortness. In contrast to these forming processes, Hot Isostatic
Pressing
(HIPing) generates no (volume- averaged)
deviatoric stresses and so is unlikely
to give rise to
either micro structural
or macroscopic defects. It is an
attractive method for removing residual porosity, which can
include surface-connected porosity as long as some form of
encapsulation is provided. It has been quite widely applied to
MMCs. However, it can be very difficult to remove residual
porosity in regions of very high ceramic content, such as
within particle clusters, and the absence of any macroscopic
Shear stresses means that such clusters are not readily
dispersed during HIPing.Furthermore, the oxide skins which
normally coat powder particles of aluminum or magnesium
are usually left intact by HIPing, leading to poor inter-particle
bonding.
2.6Spray Atomization/Co-deposition
SD is gaining recognition in the synthesis of
discontinuously
reinforced
MMCs.I.A.Ibrahim
[21],Y.Wu[22],L.Leatham[23],C.L.Buhrmaster[24].The
process involves the incorporation of fine ceramic particulates
in inert-gas-atomized droplets of the molten matrix such that
the matrix contains both liquid and solid phases. The matrix
material is usually finely dispersed in droplets by the highvelocity spray of the inert-gas jets.
The materials and structural-design advantage of this
process is that desired multiphase matrix materials or
discontinuous reinforcement, while entrained in a gas jet,
could be incorporated at a localized portion. Unwanted
reactions are avoided because the contact time and the
thermal exposure between the particulate and the partially
solidified matrix phases are reduced.
The Osprey deposition technique, a two-phase process
that has found application in Alcan productions, is a rare
technique. J.White [25] here, the molten-metal-alloy matrix
on which the reinforcement particulate is injected is atomized
by spray jets of inert gas. The solid mixture can then be
collected on a no wetting substrate in the form of a
consolidated, reinforced composite mass. A recent report on
this practice L.Leatham [23] reaffirmed that spray-atomized
products are not only free from micro segregation and low in
gas contents, but also exhibit certain characteristics that are
associated with rapid solidification. Other process benefits
over ingot metallurgy include low capital costs (less
equipment required), low operating costs (low energy
consumption and high material yields), and low overhead
costs (less stock and work-in-progress). Al-Si alloy extrusion

billets with excellent dimensional tolerances were recently

produced via the Osprey deposition technique.
2.7.In-Situ Production
Another growing route that is attracting a number of
researchers is the in-situ production of reinforcement
particles in the matrix. S.Sen[26]. Many of these researchers
have reported intrinsic uniformity in the distribution of the
reinforcing phases.Also; many processes can be used to
produce these in-situ reinforcements, including the formation
of compounds and their decompositions, redox reactions,
phase changes, nucleation, and recrystallization.
These processes usually produce periodic micro
structural features that account for the uniformly distributed
phases achieved. In this production route, particles are
obtained in the solvent (which can exist in any three states of
matter) due to chemical reaction or diffusion, which usually
occur under isothermal conditions.
Chen and Chung have applied a new stir-casting
technique to fabricate in-situ AMCs (aluminum metal matrix
composite) containing approximately 5 vol. % TiAl3
particles. the method involved the stir casting in air of slurry
consisting of molten aluminum, TiO2 particles, and Na3 AlF6
particles. According to their report, the composites
demonstrated higher tensile strength and ductility than the
SiC-reinforced aluminum composites.

Fig (1)A comparison of (a) ultimate tensile strength

(b) Hardness and (c) Elongation of some Al-Si composites
3.0.MACHINING
s.ramarattan[27]. Machining of PMMCs
presents a significant challenge to the industry since a
number of reinforcement materials are significantly harder
than the commonly used high speed steel [HSS] tools and
carbide tools. The reinforcement phase causes rapid abrasive
tool wear; thus the widespread usage of PMMCs is
considerably impeded by their poor machinablity and high
machining costs.
Brun et al[ 28] who related the tool wear rate, mainly due
to abrasion, to the tool hardness.further,they suggested using
lower cutting speeds to reduce the cutting temperature, which
accelerates adhesion and diffusion wear and thermally
weakens the tool. Since aluminum tends to seize on the tool
face and since the grain boundaries are the sites of seizure.
Stress on the cutting edge when machining metal matrix.
Mechanical loads
-considerable abrasion caused by contact with fibers or
particles.

- High dynamic loads caused by reinforcement impacts at the

cutting edge
-alternating stress resulting from inhomongenity of the work
piece material.
Thermal loads:
- Relatively low cutting temperature (limited by the melting
temperature of the work piece matrix material).
-high local temperature generated by intensive micro contact
between the cutting edge and reinforcement
Winert[29] attributed the wear of the carbide tools to
the abrading Al 2O3 particles that form on the tool surface
and rub the tool in the direction of chip flow.however,pulledout sic particles could also lead to the same effect since sic
particles are harder than tungsten carbide(WC).
Several
researchers
indicated
that
PCD
(polycrystalline diamond) tools are the only tool material that
is capable of providing a useful life during machining of
SiC/Al PMMCs. PCD is harder than Al 2O3 and SiC, and does
not have a chemical react with the work piece material.
Tomac [30] compared the performance of CVD
( chemical vapor deposition) inserts to that of TiN,Ti(CN) and
Al2O3 coated tools.CVD tools offered better overall
performance than the other coated tools. Lane [31] studied
the performance of different CVD tools with thin coating
films failed catastrophically. During end milling of
20%SiC/Al , PMMCs. The tool failure was attributed to the
spalling of the coating and consequent damage to the
relatively soft carbide substrate. The inherent brittleness of
the ceramic layer and increased friction a cross the tool rake
face are the reasons behind spalling.CVD tools with thin
coating films cannot take advantage of the tough tungsten
carbide substrate since the cobalt present in the binder leads
to the graphitization of the diamond during the coating
deposition process. On the other hand,CVD tools with thick
brazed films showed superior performance.Eventually,the
authors recommended carrying further research and
development on the brazing alloy to achieve higher wetness
and stronger braze joint.
PCD tools with a grain size of 25m better withstand
abrasion wear by micro cutting than tools with a grain size is
not beneficial to the tool life, but rather causes significant
deterioration in the surface finish. This is because PCD grains
with the size greater than 25m are easily pulled out of the
cutting edge. Researchers at Dura clan USA[32] recommend
using PCD tools in turning Al356/20%SiCp composites at
speeds upto 600m/min.Units.

Fig(2)Tribological System in the Machining of MMC

Materials
3.1Turning and Milling
The authors worked on turning of MMC with CBN,
PDC, WC and DCC tools, compared the tool wear, and
studied the effects of turning parameters.L.Luliano[33] It was
first noted that tool wear of WC tools was independent of
cutting speed and temperature, then a self-propelled rotary
WC tool was used to rough turn a SiC whisker reinforced Al
alloy. The distribution of wear prolonged the WC tool to such
an extent that its tool life was comparable to that of a PCD
tool and the subsurface damage was comparable to that
produced by a PCD tool.
The nature of machining highly abrasive MMCs means,
in reality, that tool life considerations are of overriding
importance. Coarse grained PCD (25 mm) is significantly
more wear resistant than finer grain size grades of PCD when
machining MMCs. A summary of recommended machining
condition is given in Table 1. Despite the controversy in
explaining the mechanism behind the tool wear at different
feed rates, all reviewed literature recommends using feed
rates and depths of cut that are as aggressive as possible
during the roughing operations.
Table-1 Recommended parameters for machining
Cutting speed Feed rate
Depth of cut
m/min
Mm/rev
mm
Turning 300-900
0.2-0.6
<5.0
milling
200-1000
0.1-0.4
<3.0
DURALCAN [32] recommends roughing at the
maximum practical feed rate and depth of cut (DOC),
followed by a single finishing pass at a lower feed rate and
DOC. For general-purpose roughing, where surface finish is
not critical, start at 500 m/min, 0.4 mm/rev, and a 1.5
mm.DOC. Flood coolant should be applied only if chip
clearing or built-up edge (BUE) is a problem. Tool wear is
more rapid during finishing, owing to the lower feed rate and
DOC. The actual settings will depend upon the critical radii
of certain features and on the required surface finish. Typical
parameters are 600 m/min, 0.13 mm/rev, and a 0.5 mm DOC.
The DOC should never exceed half of the insert's leg length,
and the feed should not exceed half of the nose radius. These
precautions will reduce the likelihood of fracture of the PCD
cutting edge and of poor surface finish on the work piece.
(Note that the rake and clearance angles for these inserts will
generally be the same as for an unreinforced aluminum alloy.)
Other results indicates M.El.Gallab [33], that the cost of PCD
tools could be justified by using dry cutting at feed rates as
high as 0.45 mm /rev, cutting speeds of 894 m/min and a
depth of cut of 1.5 mm.With these cutting parameters,
the relatively small built-up edge formed on the tool
protects it from further wear by abrasion and micro cutting.
Polycrystalline tools with zero rake angle and large tool nose
radii are recommended for the roughing operations.
3.2 DRILLING
HSS twist drills are not recommended to use to drill
composites.Standard-twist WC-tipped or solid drills are
suitable for prototyping.However, PCD-tipped drills are
recommended to be used in production. Because of the
abrasive nature of the MMC, point dwell by the drill must be

prevented. Adequate feed is essential to drill performance. For

drills 3-15 mm in diameter, a good guideline is to program a
feed of d 1.5/75 (in mm/rev) [32], where d is the drill
diameter in millimeters. Evacuation of the abrasive chips is
another, more complicated problem. Flute design, point
design, and the use of coolant are all important. Coolant-fed
drills offer the most effective chip clearing from deep holes,
but flood cooling with 5% water-soluble oil is usually
adequate for shallow holes. Point grinds with compound
angles and extra relief can break chips into smaller, easier-toclear curls finally, never drill more than three drill
diameters deep without retracting the drill to allow chip
clearing.
4.0 ECONOMICS
In mass production, machining time far outweighs
cutting-tool cost. For conventional aluminum alloys and cast
iron, expendable cutting-tool costs are typically less than 5%
of the total machining cost. For the composites, tool cost can
increase to 30%, but total machining cost still compares
favorably to that for machining cast iron, because diamond
tools permit equal or faster cutting speeds. Switching from
carbide tools to diamond als changes machining strategy.
First, carbide inserts are usually indexed when their wear
causes loss of dimension or finish on the work piece, and are
then discarded after the last index. This is also true of thinfilm CVDD inserts.However, worn PCD inserts can be
resharpened once or twice, though subsequent performance
can vary depending on insert condition and resharpening
technique. Second, because of the higher initial cost of
diamond, it is more important to program the tool path to
use both edges of each corner for additional savings. Finally,
the output of multiple spindle machines is generally limited
by the slowest operation. Often, the faster speeds used with
diamond tools allow balancing these simultaneous operations,
further reducing the cycle time.
5.0 CONCLUSION
The impact resistance tests revealed the improvement of
impact energies as a result of reduction in preforms initial
density (SiC volume fraction). The reason lies in the higher
volume fraction of aluminum as the ductile phase, in addition
to the lower value of residual porosity in the final
microstructure of composites fabricated on the lower
Initially dense performs. The other conclusion is the
improvement of impact energy with an increase in SiC mean
particle size.
The aluminum alloy hard particle composite can successfully
be synthesized by solidification process (stir casting
or
vortex technique). Aluminum composite so developed exhibit
uniform distribution of the particle in the matrix and good
interface bonding between the ceramic phase and the metallic
matrix.
Aluminum composite provides higher wear resistance than
those of the base alloys in all tribo-conditions.
In case of high stress abrasive wear, the improvement is noted
to be more at low load and finer abrasive size. Beyond a
critical load and abrasive size, the composite exhibits more or
less same wear rate to that of base alloy. Wear rate increases
almost linearly with the applied load.
The machining of the matrix alloy the tool life
difference between cutting tools was larger than that in the
machining of the composite. The tool life decreased with an

increase in the cutting speed for tools in all cutting

conditions.
The major tool wear forms were the combination of
flank wear and rounding of the nose. The removal of the tool
coated layer from the substrate material and BUE formation
appeared. When machining composites at lower cutting
speed. However, edge chipping and nose rounding was
evident due to high temperature and stresses at the cutting
edge.
The cutting speed was the influential machining
parameter on the tool wear. The tool wear increased
considerably with increasing cutting speed.Thecutting
parameters of the work piece stresses and surface
fininsh.surface finish, however a reflection of the tool flank
wear. Surface roughness is good as the cutting speed
increases. Feed rate is the factor, which has greater influence
on surface roughness, followed by cutting speed and %
volume fraction of SiC. The feed increases surface finish
improves only up to certain level after that it starts
deteriorates.The interaction between cutting speed and feed
rate has more influence comparing with other interactions on
surface roughness on the machining of Al/SiC-MMC
composites
The PCD tool exhibits superior wear resistance and
hence it can be recommended for proper machining of
Al/SiC-MMC without use of coolant.The CBN and PCD
tools are recommended for better surface finish during
machining of Al/SiC-MMC.Use of cutting fluid during
machining increases tool wear and surface roughness. The
circulation of cutting fluid during machining decreases the
temperature at the chip formation zone, which increases the
matrix strength and helps to adhere the reinforced particles
on the lower side of the chip and cutting edge of the tool,
which will resist together cutting the metal during
machining.
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