Image result for metal matrix composites www.slideshare.net 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.

1. Metal Matrix Composite ( MMC )
A Project Training Report Submitted
In Partial Fulfilment of the Requirement
For the Degree Of
Bachelor of Technology
Student Name : Shashwat Mishra Roll No: 201410102110068
Co-ordinator : Er Amit Singh
FACULTY OF MECHANICAL ENGINEERING
INSTITUTE OF TECHNOLOGY
SHRI RAMSWAROOP MEMORIAL UNIVERSITY
September , 2017

2. ACKNOWLEDGEMENT
On the occasion of presenting this seminar report I wish to express my deep gratitude to all the
people who have contributed to the completion of this seminar. First of all I would like to thank
Rohit Kumar Singh (Assistant Professor, Department Of Mechanical Engineering) for being my
guide and for the help granted by him and providing me with all facility and guidance.
I would also take this opportunity to express my heartfelt Professor Dr. Niraj Gupta. ( HOD
Department Of Mechanical Engineering) for his valuable support and cooperation in the
presentation of this paper.
I am thankful to all faculties for their lively discussions and suggestions. Finally I would like to
thank my friends who have given me required suggestions for the successful completion of my
seminar.

3. Contents
1 Composition
Matrix
Reinforcement
2 Manufacturing and forming methods
Solid state methods
Liquid state methods
Semi-solid state methods
Vapor deposition
2.5 In-situ fabrication technique
3 Residual stress
4 Applications
5 References
6 External links

4. INTRODUCTION
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. An MMC is complementary to a cermet.
Composition
MMCs are made by dispersing a reinforcing material into a metal matrix. The reinforcement
surface can be coated to prevent a chemical reaction with the matrix. For example, carbon
fibers are commonly used in aluminium matrix to synthesize composites showing low density
and high strength. However, carbon reacts with aluminium to generate a brittle and water-
soluble compound Al4C3 on the surface of the fibre. To prevent this reaction, the carbon fibres
are coated with nickel or titanium boride.
Matrix
The matrix is the monolithic material into which the reinforcement is embedded, and is
completely continuous. This means that there is a path through the matrix to any point in the
material, unlike two materials sandwiched together. In structural applications, the matrix is
usually a lighter metal such as aluminum, magnesium, or titanium, and provides a compliant
support for the reinforcement. In high-temperature applications, cobalt and cobalt–nickel alloy
matrices are common.
Reinforcement
The reinforcement material is embedded into a matrix. 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 can be either continuous, or discontinuous. Discontinuous MMCs can be
isotropic, and can be worked with standard metalworking techniques, such as extrusion,
forging, or rolling. In addition, they may be machined using conventional techniques, but
commonly would need the use of polycrystaline diamond tooling (PCD).

5. Continuous reinforcement uses monofilament wires or fibers such as carbon fiber or silicon
carbide. Because the fibers are embedded into the matrix in a certain direction, the result is an
anisotropic structure in which the alignment of the material affects its strength. One of the first
MMCs used boron filament as reinforcement. Discontinuous reinforcement uses "whiskers",
short fibers, or particles. The most common reinforcing materials in this category are alumina
and silicon carbide.
Manufacturing and forming methods
MMC manufacturing can be broken into three types—solid, liquid, and vapor.
Solid state methods
Powder blending and consolidation (powder metallurgy): Powdered metal and discontinuous
reinforcement are mixed and then bonded through a process of compaction, degassing, and
thermo-mechanical treatment (possibly via hot isostatic pressing (HIP) or extrusion)
Foil diffusion bonding: Layers of metal foil are sandwiched with long fibers, and then pressed
through to form a matrix

6. Liquid state methods
Electroplating and electroforming: A solution containing metal ions loaded with reinforcing
particles is co-deposited forming a composite material
Stir casting: Discontinuous reinforcement is stirred into molten metal, which is allowed to
solidify
Pressure infiltration: Molten metal is infiltrated into the reinforcement through use a kind of
pressure such as gas pressure
Squeeze casting: Molten metal is injected into a form with fibers pre-placed inside it
Spray deposition: Molten metal is sprayed onto a continuous fiber substrate
Reactive processing: A chemical reaction occurs, with one of the reactants forming the matrix
and the other the reinforcement
Semi-solid state methods
Semi-solid powder processing: Powder mixture is heated up to semi-solid state and pressure is
applied to form the composites.
Vapor deposition
Physical vapor deposition: The fiber is passed through a thick cloud of vaporized metal, coating
it.
In-situ fabrication technique
Controlled unidirectional solidification of a eutectic alloy can result in a two-phase
microstructure with one of the phases, present in lamellar or fiber form, distributed in the
matrix.
Residual stress
MMCs are fabricated at elevated temperatures, which is an essential condition for diffusion
bonding of the fiber/matrix interface. Later on, when they are cooled down to the ambient

7. temperature, residual stresses (RS) are generated in the composite due to the mismatch
between the coefficients of the metal matrix and fiber. The manufacturing RS significantly
influence the mechanical behavior of the MMCs in all loading conditions. In some cases,
thermal RS are high enough to initiate plastic deformation within the matrix during the
manufacturing process.
Applications
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High performance tungsten carbide cutting tools are made from a tough cobalt matrix
cementing the hard tungsten carbide particles; lower performance tools can use other metals
such as bronze as the matrix.
Some tank armors may be made from metal matrix composites, probably steel reinforced with
boron nitride, which is a good reinforcement for steel because it is very stiff and it does not
dissolve in molten steel.
Some automotive disc brakes use MMCs. Early Lotus Elise models used aluminum MMC rotors,
but they have less than optimal heat properties and Lotus has since switched back to cast-iron.
Modern high-performance sport cars, such as those built by Porsche, use rotors made of carbon
fiber within a silicon carbide matrix because of its high specific heat and thermal conductivity.
3M developed a preformed aluminum matrix insert for strengthening cast aluminum disc brake
calipers, reducing weight by half compared to cast iron while retaining similar stiffness. 3M has
also used alumina preforms for AMC pushrods.
Ford offers a Metal Matrix Composite (MMC) driveshaft upgrade. The MMC driveshaft is made
of an aluminum matrix reinforced with boron carbide, allowing the critical speed of the
driveshaft to be raised by reducing inertia. The MMC driveshaft has become a common
modification for racers, allowing the top speed to be increased far beyond the safe operating
speeds of a standard aluminum driveshaft.
Honda has used aluminum metal matrix composite cylinder liners in some of their engines,
including the B21A1, H22A and H23A, F20C and F22C, and the C32B used in the NSX.
Toyota has since used metal matrix composites in the Yamaha-designed 2ZZ-GE engine which is
used in the later Lotus Lotus Elise S2 versions as well as Toyota car models, including the

8. eponymous Toyota Matrix. Porsche also uses MMCs to reinforce the engine's cylinder sleeves in
the Boxster and 911.
The F-16 Fighting Falcon uses monofilament silicon carbide fibers in a titanium matrix for a
structural component of the jet's landing gear.
Specialized Bicycles has used aluminum MMC compounds for its top of the range bicycle frames
for several years. Griffen Bicycles also made boron carbide-aluminum MMC bike frames, and
Univega briefly did so as well.
Some equipment in particle accelerators such as Radio Frequency Quadrupoles (RFQs) or
electron targets use copper MMC compounds such as Glidcop to retain the material properties
of copper at high temperatures and radiation levels.[9][10]
Copper-silver alloy matrix containing 55% by volume diamond particles, known as Dymalloy, is
used as a substrate for high-power, high-density multi-chip modules in electronics for its very
high thermal conductivity.
Aluminium-Graphite composites are used in power electronic modules because of their high
thermal conductivity, the adjustable coefficient of thermal expansion and the low density.
MMCs are nearly always more expensive than the more conventional materials they are
replacing. As a result, they are found where improved properties and performance can justify
the added cost. Today these applications are found most often in aircraft components, space
systems and high-end or "boutique" sports equipment. The scope of applications will certainly
increase as manufacturing costs are reduced.
In comparison with conventional polymer matrix composites, MMCs are resistant to fire, can
operate in wider range of temperatures, do not absorb moisture, have better electrical and
thermal conductivity, are resistant to radiation damage, and do not display outgassing. On the
other hand, MMCs tend to be more expensive, the fiber-reinforced materials may be difficult to
fabricate, and the available experience in use is limited.

9. Metal-Matrix Composites for Space Applications
From the onset of the space era, both organic-matrix and metal-matrix composites (MMCs),
with high specific stiffness and near-zero coefficient of thermal expansion (CTE), have been
developed for space applications. Of the organic-matrix composites, graphite/epoxy (Gr/Ep) has
been used in space for truss elements, bus panels, antennas, wave guides, and parabolic
reflectors in the past 30 years. MMCs possess high-temperature capability, high thermal
conductivity, low CTE, and high specific stiffness and strength. Those potential benefits
generated optimism for MMCs for critical space system applications in the late 1980s.1,2 The
purpose of this article is to detail the history, status, and opportunities of MMCs for space
applications.
The extreme environment in space presents both a challenge and opportunity for material
scientists. In the near-earth orbit, typical spacecraft encounter naturally occurring phenomena
such as vacuum, thermal radiation, atomic oxygen, ionizing radiation, and plasma, along with
factors such as micrometeoroids and human-made debris. For example, the International Space
Station, during its 30-year life, will undergo about 175,000 thermal cycles from +125°C to –
125°C as it moves in and out of the Earth’s shadow. Re-entry vehicles for Earth and Mars
missions may encounter temperatures that exceed 1,500°C. Critical spacecraft missions,
therefore, demand lightweight space structures with high pointing accuracy and dimensional
stability in the presence of dynamic and thermal disturbances. Composite materials, with their
high specific stiffness and low coefficient of thermal expansion (CTE), provide the necessary
characteristics to produce lightweight and dimensionally stable structures. Therefore, both
organic-matrix and metal-matrix composites (MMCs) have been developed for space
applications.
Despite the successful production of MMCs such as continuous-fiber reinforced
boron/aluminum (B/Al), graphite/ aluminum (Gr/Al), and graphite/ magnesium (Gr/Mg),3–7 the
technology insertion was limited by the concerns related to ease of manufacturing and
inspection, scale-up, and cost. Organic-matrix composites continued to successfully address the
system-level concerns related to microcracking during thermal cycling and radiation exposure,
and electromagnetic interference (EMI) shielding; MMCs are inherently resistant to those
factors. Concurrently, discontinuously reinforced MMCs such as silicon-carbide particulate (p)
reinforced aluminum (SiCp/Al) and Gp/Al composites were developed cost effectively both for
aerospace applications (e.g., electronic packaging) and commercial applications. This paper
describes the benefits, drawbacks, potential for the various MMCs in the U.S. space program.

10. HISTORICAL PERSPECTIVE
Historically, MMCs, such as steel-wire reinforced copper, were among the first continuous-fiber
reinforced composites studied as a model system. Initial work in late 1960s was stimulated by
the high-performance needs of the aerospace industry. In these development efforts,
performance, not cost, was the primary driver. Boron filament, the first high-strength, high-
modulus reinforcement, was developed both for metal- and organic- matrix composites.
Because of the fiber-strength degradation and poor wettability in molten-aluminum alloys, the
early carbon fibers could only be properly reinforced in organic-matrix composites. Therefore,
the development of MMCs was primarily directed toward diffusion-bonding processing. At the
same time, optimum (air stable) surface coatings were developed for boron and graphite fibers
to facilitate wetting and inhibit reaction with aluminum or magnesium alloys during processing.
METAL-MATRIX COMPOSITE PROCESSING
Three processing methods have been primarily used to develop MMCs: high-pressure diffusion
bonding, casting, and powder-metallurgy techniques. More specifically, the diffusion-bonding
and casting methods have been used for continuous- fiber reinforced MMCs. Discontinuously
reinforced MMCs have been produced by powder metallurgy and pressure-assist casting
processes. MMCs such as B/Al, Gr/Al, Gr/Mg, and Gr/ Cu have been manufactured by diffusion
bonding for prototype spacecraft components such as tubes, plates, and panels.
Properties
Table I lists the typical properties of a few continuous-fiber reinforced MMCs. Generally,
measured properties of as-fabricated MMCs are consistent with the analytically predicted
properties of each composite. The primary advantage of MMCs over counterpart organic-
matrix composites is the maximum operating temperature. For example, B/Al offers useful
mechanical properties up to 510°C, whereas an equivalent B/Ep composite is limited to about
190°C. In addition, MMCs such as Gr/Al, Gr/Mg, and Gr/Cu exhibit higher thermal conductivity
because of the significant contribution from the metallic matrix.
Properties of discontinuously reinforced aluminum (DRA) composites for spacecraft and
commercial applications. DRA is an isotropic MMC with specific mechanical properties superior
to conventional aerospace materials. For example, DWA Aluminum Composites has produced

11. MMCs using 6092 and 2009 matrix alloys for the best combination of strength, ductility, and
fracture toughness, and 6063 matrix alloy to obtain high thermal conductivity. Similarly, Metal
Matrix Cast Composite (MMCC) Inc. has produced graphite particulate-reinforced aluminum
composites for the optimum combination of high specific thermal conductivity and CTE.
APPLICATIONS
While the desire for high-precision, dimensionally stable spacecraft structures has driven the
development of MMCs, applications thus far have been limited by difficult fabrication
processes. The first successful application of continuous-fiber reinforced MMC has been the
application of B/Al tubular struts used as the frame and rib truss members in the mid-fuselage
section, and as the landing gear drag link of the Space Shuttle Orbiter (Figure 1). Several
hundred B/Al tube assemblies with titanium collars and end fittings were produced for each
shuttle orbiter. In this application, the B/Al tubes provided 45% weight savings over the
baseline aluminum design.

12. Mid-fuselage structure of Space Shuttle Orbiter showing boron-aluminum tubes. (Photo
courtesy of U.S. Air Force/NASA).The P100/6061 Al high-gain antenna wave guides/ boom for
the Hubble Space Telescope (HST) shown (a-left) before integration in the HST, and (b-right) on
the HST as it is deployed in low-earth orbit from the space shuttle orbiter.
The major application of Gr/Al composite is a high-gain antenna boom (Figures
2a and 2b) for the Hubble Space Telescope made with diffusion-bonded sheet of P100 graphite
fibers in 6061 Al. This boom (3.6 m long) offers the desired stiffness and low CTE to maintain
the position of the antenna during space maneuvers. In addition, it provides the wave-guide
function, with the MMC’s excellent electrical conductivity enabling electrical-signal
transmission between the spacecraft and the antenna dish. Also contributing to its success in
this function is the MMC’s high dimensional stability—the material maintains internal
dimensional tolerance of ±0.15 mm along the entire length. While the part currently in service
is continuously reinforced with graphite fibers, replacement structures produced with less
expensive DRA have been certified.
Like the Gr/Al structural boom, a few MMCs have been designed to serve multiple purposes,
such as structural, electrical, and thermal-control functions. For example, prototype Gr/Al
composites were developed as structural radiators to perform structural, thermal, and EMI
shielding functions.5 Also, Gr/Cu MMCs with high thermal conductivity were developed for
high-temperature structural radiators.6 A DRA panel is used as a heat sink between two printed
circuit boards to provide both thermal management and protection against flexure and
vibration, which could lead to premature failure of the components in the circuit board.
In technology-development programs sponsored by the U.S. Defense Advanced Research
Projects Agency and the U.S. Air Force, graphite/magnesium tubes for truss-structure
applications have been successfully produced (jointly by Lockheed Martin Space Systems of
Colorado and Fiber Materials of Maine) by the filament-winding vacuum-assisted casting
process. Figures 3a and 3b show a few of the cast Gr/Mg tubes (50 mm dia ´ 1.2 m long) that
were produced to demonstrate the reproducibility and reliability of the fabrication method.
Of the DRA composites, reinforcements of both particulate SiCp/Al and whisker (w) SiCw/Al
were extensively characterized and evaluated during the 1980s. Potential applications included
joints and attachment fittings for truss structures, longerons, electronic packages, thermal
planes, mechanism housings, and bushings. Figures 4a and 4b show a multi-inlet SiCp/Al truss
node produced by a near net-shape casting process.

13. Discontinuously reinforced aluminum MMCs for electronic packaging applications: (a-top)
SiCp/Al electronic package for a remote power controller (photo courtesy of Lockheed Martin
Corporation), and (b-bottom) cast Grp/Al components (photo courtesy of MMCC, Inc.).
Because of their combination of high thermal conductivity, tailorable CTE (to match the CTE of
electronic materials such as gallium arsenide or alumina), and low density, DRA composites are
especially advantageous for electronic packaging and thermal-management applications.8,9
Several SiCp/Al and Grp/Al (Figures 5a and 5b) electronic packages have been space-qualified
and are now flown on communication satellites and Global Positioning System satellites. These
components are not only significantly lighter than those produced from previous metal alloys,
but they provide significant cost savings through net-shape manufacturing.9 DRA is also used
for thermal management of spacecraft power semiconductor modules in geosynchronous
earth-orbit communication satellites, displacing Cu/W alloys with a much higher density and
lower thermal conductivity, while generating a weight savings of more than 80%. These
modules are also used in a number of land-based systems, which accounts for an annual
production near 1 million piece-parts. With these demonstrated benefits, application of DRA
MMCs for electronic packages will continue to flourish for space applications.
STATUS AND FUTURE
When continuous-fiber reinforced MMCs were no longer needed for the critical strategic
defense system/missions, the development of those MMCs for space applications came to an
abrupt halt. Major improvements were still necessary, and manufacturing and assembly
problems remained to be solved. In essence, continuous-fiber reinforced MMCs were not able
to attain their full potential as an engineered material for spacecraft applications. During the
same period, Gr/Ep, with its superior specific stiffness and strength in the uniaxially-aligned
fiber orientation, became an established choice for tube structures in spacecraft trusses. Issues
of environmental stability in the space environment have been satisfactorily resolved.
However, particle-reinforced metals provide very good specific strength and stiffness, isotropic
properties, ease of manufacturing to near net shape, excellent thermal and electrical
properties, and affordability, making discontinuous MMCs suitable for a wide range of space
applications. The high structural efficiency and isotropic properties of discontinuously

14. reinforced metals provide a good match with the required multiaxial loading for truss nodes,
where high loads are encountered. DRA is a candidate for lightly-loaded trusses, while
discontinuously reinforced Ti (DRTi) is more favorable for highly-loaded trusses. DRTi, now
commercially available in both the United States and Japan, offers excellent values of absolute
strength and stiffness as well as specific strength and stiffness.
A wide range of additional applications exist for discontinuously reinforced metals.
Opportunities for thermal management and electronic packaging include radiator panels and
battery sleeves, power semiconductor packages, microwave modules, black box enclosures,
and printed circuit board heat sinks. For example, the DSCS-III, a military communication
satellite, uses more than 23 kg of Kovar for microwave packaging. Replacing this metal with
Al/SiCp, which is used for thermal management in land-based systems, would save more than
13 kg of weight and provide a cost savings over Kovar components. Potential satellite
subsystem applications include brackets and braces currently made from metals with lower
specific strength and stiffness, semimonocoque plates and cylinders, fittings for organic-matrix
composite tubes, hinges, gimbals, inertial wheel housings and electro-optical subsystems.
MMCs are routinely included as candidate materials for primary and secondary structural
applications. However, simply having the best engineered material with extraordinary strength,
stiffness, and environmental resistance is no guarantee of insertion. The availability and
affordability of continuously reinforced MMC remains a significant barrier to insertion.
Designers who often make the decision of material selection must become more familiar with
the properties, commercial availability and life-cycle affordability of existing discontinuously
reinforced metals. Material performance must be integrated with innovative design and
affordable manufacturing methods to produce systems and subsystems that provide tangible
benefits. However, in the absence of system-pull and adequate resources, it is difficult to
surmount the technical and cost barriers.
Recognizing that defense- and aerospace- driven materials need to turn to the commercial
market place, Carlson10 cited four recurring principles that will shape the future of advanced
materials such as organic-matrix and MMCs. These four principles included system solutions,
economical manufacturing processing, diverse markets, and new technologies. In terms of
system solutions, the decision regarding designs, processes and materials must be made
synergistically to attain maximum benefit. No single mission or system application can sustain
the cost of developing new materials and processes. Thus, the use of DRA in diverse markets

15. such as automotive, recreational, and aircraft industries has made DRA MMC affordable for
spacecraft applications such as electronic packaging. Building upon the success of DRA in
electronic packaging and in structural applications in the automotive and aeronautical fields,
DRA is also being evaluated for truss end fittings, mechanism housings, and longerons.
During the development of MMCs, significant advancements were made on the fundamental
science and technology front, including a basic understanding of composite behavior, fiber-
matrix interfaces, surface coatings, manufacturing processes, and thermal-mechanical
processing of MMCs. Subsequently, the technology experience benefited the latter
development of high-temperature intermetallic- matrix composites. (Research activities that
will be required to support more widespread use of MMCs for space applications have been
discussed in Reference 9.)
Lightweight, stiff, and strong Gr/Al and DRA MMCs will continue to be included in material
trade studies for spacecraft components, as MMCs offer significant payoffs in terms of
performance (e.g., high precision, survivable) for specific systems. For successful use in space
applications, continuous MMCs must become more affordable, readily available,
reliable/reproducible, and repairable, exhibiting equivalent or better properties than competing
graphite/ epoxy or metallic parts. Discontinuous metals, with their broad range of functional
properties including high structural efficiency and isotropic properties, offer the greatest
potential for a wide range of space-system applications. A good understanding provided by
years of research, and a strong industry based on applications in the automotive, recreation,
aeronautical, and land-based communications markets, have established the foundation for
cost-effective insertion of discontinuously reinforced metals in the space industry.

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