COMPOSITE MATERIALS AND

TECHNOLOGY

METAL MATRIX
COMPOSITES
PROCESSINGBY

HARISH

INTRODUCTION
Composite material is composed of two

distinct phases.
Matrix phase
Dispersed (reinforcing) phase
Matrix phase commonly known as the primary

phase and dispersed phase known as secondary

phase
Dispersed phase is stronger than compared to
matrix phase hence called as the reinforcing
phase

CLASSIFICATION SYSTEMS OF COMPOSITE MATERIALS

Classification of composites (based on

matrix material)
Metal Matrix Composites (MMC)
Ceramic Matrix Composites (CMC)
Polymer Matrix Composites (PMC)

Classification of composite materials

(based on reinforcing material structure)

Particulate Composites
Fibrous Composites
Laminate Composites

REINFORCEMENTS
TYPES OF REINFORCEMENT
Continuous fibers.
Discontinuous fibers.
Whiskers.
Particulates.
Wires.

ROLE OF REINFORCEMENTS
Density
Major load bearing
Strengthen and stiffen
Improved temperature capability
Reduced thermal expansion coefficient
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REINFORCEMENT COATINGS

In general, coatings on the fibers offer the following

advantages:
Protection of fiber from reaction and diffusion with the

matrix by serving as a diffusion barrier.

Prevention of direct fiber-fiber contact.
Promotion of wetting and bonding between the fiber

and the matrix.

Relief of thermal stresses or strain concentrations

between the fiber and the matrix.

Protection of fiber during handling.
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PARTICULATE REINFORCED
MMCs
Particles used to increase the modulus of the matrix and to

decrease the permeability and ductility of the matrix.

Particles are also used to produce inexpensive composites

Figure : Photo Micro-graphic image of Al-SiCP

The reinforcement surface will be coated to prevent a

chemical reaction with the matrix

SHORT FIBER-REINFORCED MMCS

Production rates for short-fiber composites are rapid
The reinforcement does not always serve a purely

structural task (reinforcing the compound), but is also

used to change physical properties such as wear
resistance, friction coefficient, or thermal conductivity.
The reinforcement will be either continuous or
discontinuous as shown figure (a) and (b)

[a]

[b]

CHOICE OF PRODUCTION TECHNOLOGY

THE
Preservation
of reinforcement strength
Minimization of reinforcement damage
Promotion of wetting and bonding between the

matrix and reinforcement

Flexibility that allows proper backing, spacing
and orientation of the reinforcements within the
matrix.

STIR CASTING

Discontinuous reinforcement is stirred into molten metal,

which is allowed to solidify.
Stir casting characterized by following features:
Content of dispersed phase is limited (usually not more than
30% vol.).

Distribution of dispersed phase throughout the matrix is not

perfectly homogeneous
local clouds are present(clusters)
Theres gravity segregation to the dispersed phase due to
difference in the densities of dispersed and matrix phase.
simple and low cost

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SQUEEZE CASTING or PRESSURE INFILTRATION:

Involves forcing a liquid metal into a fibrous or

particulate preform, and Pressure is applied until

solidification is complete.
Squeeze casting infiltration has the following steps:
1. A molten metal of predetermined amount is
poured into the lower mould half
2. The upper movable mould half is moved
downwards and it forces the liquid metal to in
filtrate
3. The Infiltrated material solidifies under the
pressure.
4. The part removed from the mould by means of the
ejector pin.

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SQUEEZE CASTING

Figure :Squeeze casting or pressure infiltration process

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SPRAY DEPOSITION:
Spray casting/deposition is a primary process of

composite production whereby the metal sprayed

onto a substrate.
Spray deposition techniques fall into distinct classes,
depending whether the droplet stream produced
from a molten bath, or by continuous feeding of cold
metal into a zone of rapid heat injection.

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IN SITU PROCESSING
This process avoids the need for intermediate formation

of the reinforcement,means the reinforcement phase is

formed in situ.
Reinforcements are formed by reaction in situ in the
metal matrix in single step.

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SOLID STATE PROCESSING:

Powder metallurgy: A forming and fabrication technique
consisting of three major processing stages.
First powdered metal or ceramic powder or discontinuous fibers

are mixed.
Then the powder is injected into a mold or passed through a die to
produce a compact of weakly cohesive structure.
The end part which formed by applying pressure may be sintered
in a proper temperature and atmosphere to produce a final
composite compact
This compact may need to undergo a secondary manufacturing
process like rolling or extrusion to produce the desired shape to
suite the application.

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DIFFUSION BONDING
In this technique layers of metal foil are sandwiched with

long fibers, and then pressed through to form a

composites.
This technique is used for making multi-layer metal
sheets.
In bi-metal process two different thin sheets are brought
into contact with each other in an alternative manner.
This arrangement may be pressed strongly for a long
period while keeping their temperature slightly high.

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