Basic of Metal Matrix Composite

1. Metal Matrix Composite
(Basic Concept and Research Aspect)
Dr B. Radha Krishnan,
Associate Professor/ Mechanical Engineering
Nadar Saraswathi College of Engineering and Technology,
Theni

2. NADAR SARASWATHI COLLEGE OF ENGINEERING AND TECHNOLOGY
• Department of Mechanical Engineering
• Established in 2010
• Approved research centre in mechanical Engineering
• Top 10 position in South Tamilnadu in past 6 years
• Research facility enriched for Composite materials

3. Why?
• Can modified the desired mechanical properties.
• Can replace the materials especially in heavy load
applications.
• Can produce the complex shape.
• Improve the performance

4. History
• 1939 – glass fiber for high temperature application.
• 1950 – Boron and Carbon fibers for rope manufacturing.
• 1960 – Polymer matrix composite

5. • 1970- Metal matrix composite for military and aerospace
applications.
• 1990- ceramic matrix composite.
- high temperature applications like aircraft engine and
power plant turbines.

6. Contribution
• Transportation industries= 33%
• Construction industries = 20%
• Marine = 12%
• Corrosion resistance materials = 12%
• Electrical appliance = 13%
• Consumer products = 5%
• Others = 5%

7. Classification

9. Classification Based on Reinforcement

10. Factors Considering for Reinforcement
• Low density, High stiffness
• High Young's Modulus
• High compression and tensile stress
• Thermal stability
• Machinability
• Economic efficiency
(Mechanical properties can change, during high temp
process)

11. Metal Matrix Composite
A metal matrix composite (MMC) is composite material with
at least two constituent parts, one being a metal necessarily,
The other material may be a different metal or another
material, such as a ceramic or organic compound.
When at least three materials are present, it is called a hybrid
composite.

12. Microstructure Analysis

13. Classifications
•Aluminium Matrix Composite
•Copper Matrix Composite
•Magnesium Matrix Composite
•Titanium Matrix Composite

14. Aluminium Matrix Composite
• It is used for manufacturing the automotive parts like Piston,
push rod, brake components, Bicycles frame.
 Low density
 Abrasion resistance
 High strength and stiffness.
 High thermal conductivity
Processed by
a) Stir Casting
b) Powder metallurgy
c) Infiltration
( Mainly reinforced with Al2O3 and SiC )

15. Copper Matrix Composite
• It was mainly applicable for electrical and electronic component
productions such as electronic relay, springs.
 Low coefficient of thermal expansion
 Good wear resistance
 Good electrical conductivity
 Good thermal conductivity
Processed by
a) Powder metallurgy
b) Infiltration
(Reinforced by Carbon fibre for continuous product, SiC, Tungsten,
Stainless steel 304 ( Long fibre))

16. Magnesium Matrix Composite
• Produce the components for racing cars, light weight automotive
breaking system, aircraft parts such as gear box, transmission system,
engine.
 Low density
 Good creep resistance
 High strength and stiffness.
 Good thermal conductivity
Processed by
a) Stir Casting
b) Powder metallurgy
c) Infiltration
(Mainly reinforced with SiC)

17. Titanium Matrix Composite
• Reinforced by continuous monofilament silicon carbide
fiber( CVD)
• Titanium boride and Titanium Carbide.

18. Titanium Matrix Composite
Process- Powder metallurgy
High strength
High stiffness
High creep and wear resistance
High thermal stability
Used for F-16 Jet landing gear, turbine engine components
and automotive engine components.

19. Selection of Materials
1. Based on the applications and issues
(Real time field applications and problems occur during the
machining process)
2. From the existing research.
(Improve the properties with percentage changing of
reinforcement)

20. Need to ensure
• Melting point of the Matrix
( eg., Al6063 - 615oC - 654oC, SiC -2,830 °C).
• Selection of process
• Essential Testing methods
1.SEM- Matrix and Reinforcement bonding
2.EDAX (Energy Dispersive X-Ray Analysis)- Chemical Composition
3.Wear Analysis
4.Hardness testing
5.Tensile and compressive ( based on application)
If machining process,
Roughness profile by SEM analysis. Wear rate
• Need to mention the existing materials properties for justification

21. • Reinforced materials grain size (Micro or Nano)
- prefer nano particles, for good interfacial bonding
• Reinforced materials should add uniformly in stir casting
process
• Process may without exceeding the material melting point,
thereby significantly lowering the risk of oxidation, phase
transformation, and excessive thermal residual stress.
ex ., Diamond-reinforced metal matrix composites (DMMC) have
great potential for wear-resistance applications due to the superior
hardness of the diamond component. Cold spray as an emerging
coating technique is able to fabricate coatings

22. Processing Methods

23. Stir Casting Process

24. • Matrix- Al, Co, Cu, Ti, Mg.
• Can maintain atmosphere by vacuum.
• Stir for , uniform melting, uniform dispose the
reinforcement.
• Need to analyse the density of materials
• Ranges of melting temperature, if raise above, may change
the properties of composite.
• Reinforced should in particulate and whisker, but whisker
is challenge one.
• Not more than 30%.
• Technology wise it was simple and low cost.

25. Powder metallurgy
process
• The conventional powder metallurgy process consists of
three main-steps: powder mixing, compacting (sintering)
and extrusion.
• To carry out the processing of MMC Through powder
metallurgy, development of powder metallurgy set up is
essential.

26. Data prediction from Existing Work
(Aluminium Matrix Composite)

27. Sl. No. Material Properties
1 Pure Al (PM) High Ductile Low strength Corrosion Resistance
2 Al-5%TiO2 (PM) Light Ductile Medium strength Corrosion Resistance
3 Al-10%TiO2 (PM) Low Ductile High strength
High Corrosion
Resistance
4 Pure Al (PM) + (HE) Ductility Medium strength High Toughness
5 Al-5%TiO2 (PM) + (HE) Wear Resistance Medium strength High Toughness
6 Al-10%TiO2 (PM) + (HE) Low Ductile High strength High Hardness
7 Pure Al (SC) High Ductile Low strength low density
8 Al-10%TiO2 (SC) High Hardness High strength Wear Resistance
9 Al-15%TiO2 (SC) Low Hardness Low strength
High Corrosion
Resistance

28. Sl. No. Material Properties
10 AA7075 (PM) Low Ductility Low strength
High Corrosion
Resistance
11 AA7075+ 5%TiO2 (PM) Medium hardnes Medium strength High Toughness
12 AA7075+ 10%TiO2 (PM) High hardness high strength Wear Resistance
13 AA7075+ 15%TiO2 (PM) High hardness Low strength
High Corrosion
Resistance
14 AA7075 (SC) High Ductility Medium strength High Toughness
15 AA7075+ 5%TiO2 (SC) Medium Ductile Medium strength Medium Hardness
16 AA7075+ 10%TiO2 (SC) High hardness High strength Wear Resistance
17 AA7075+ 15%TiO2 (SC) High hardness Low strength
High Corrosion
Resistance

29. Thank you for everyone