This document presents the design and development of a metal reinforced fibre composite. The project aims to fabricate a new composite made of PBO fibres reinforced in an aluminum-magnesium eutectic alloy matrix. The composite will be produced using vacuum liquid metal melt infiltration. The goals are to improve properties like strength, stiffness, impact resistance, and reduce density compared to the metal alloy alone. Testing will characterize the mechanical properties and microstructure of the composite.

2. DESIGN AND DEVELOPMENT OF
METAL REINFORCED FIBRE
COMPOSITES

3. PROJECT MEMBERS :
RAJESH .L. (10109114043)
MOHAMMED ABDUL BAAQI (10109114305)
EDWIN RAJ (10109114301)
KALANDAR BASEER ALI (10109114021)
PROJECT GUIDE : PROJECT CO-ORDINATOR:
Dr. MOHD.F. SHABIR Dr. S. SATHISH

4. ABSTRACT
The word COMPOSITES means composition of
materials are engineered or naturally occurring
materials made from two or more constituent
materials with significantly different physical and
chemical properties which remains separate and
distinct at the macroscopic or microscopic within the
finished structure.

5. PROBLEM DEFINITION
To design, fabricate and conduct a mechanical characterization of a new
hybrid (PBO reinforced al-mg eutectic alloy) composite that has the
following properties like;
1. High ultimate tensile strength
2. High young’s modulus
3. Low density
4. High specific strength
5. High stiffness
6. Fracture toughness
7. High impact strength
8. High hardness
Constraints: temperature and oxygen presence
Variables: cooling rate, volume factor.
Beyond the scope: interface and inter phase studies, cooling rate.

6. OBJECTIVES
Objectives: To fabricate a new metal reinforced polymer composites most
specifically a higher modulus PBO fibre reinforced aluminium magnesium
eutectic alloy metal matrix composites by vacuum liquid metal melt
infiltration technique and investigate the mechanical characteristics of the
PBO reinforced al-mg alloy MMC. Some important objectives:
1. To obtain a unidirectional polymer reinforced MMC.
2. To obtain a lower specific weight PRMMC than MM alone.
3. To obtain a higher specific tensile modulus PRMMC than MM alone.
4. To obtain a higher specific tensile strength PRMMC than MM alone.
5. To obtain a higher fracture toughness PRMMC than MM alone.
6. To obtain a higher impact toughness PRMMC than MM alone.
7. To obtain a higher damage tolerance PRMMC than MM alone.
8. To obtain the bonding nature of PBO fibre and MM.
9. To obtain the thermal degradation in the properties of PRMMC.
10.To obtain the low cost production.

7. SCOPE OF RESEARCH
Scope is limited to metal matrix composites reinforced with
high performance polymer fibres that are produced by
infiltration technique. The scope is also limited in improving
some of the mechanical properties so as to enable it to be
used for light weight high performance applications.

8. METHODOLOGY
Electro less Cu coating of
PBO filament fibre
Placing fibres in
orientation in side mould
of desired test specimen
dimensions
Evacuating / providing
inert atmosphere for
mould to prevent
thermal degradation &
oxidation of polymer
fibres and metal matrix
(also coated Cu)
Pouring liquefied metal
inside the mould-
infiltration
Water cooling the mould
Performing standard tests
SEM characterization
Publishing the findings

9. DESIGN CALCULATION
The property of composite material is given by,
PC = Vf Pf + Vmaterialmatrix Pmaterial matrix
The total volume is given by,
Vt =Vf + Vmaterial matrix
Then,
Vf= Vtf /Vt
Vmaterial matrix = Vtmaterial matrix /Vt
Here,
Vtf orVt material matrix = E / ρg
Where,
PC= Property of composite material,
Pf= Property of fiber,
Pmaterial matrix= Property of material matrix,
Vt = Total volume of composite material,
Vf = Volume of fiber,
Vmaterial matrix =Volume of material matrix,
Vtf= Total volume occupied by the fiber,
Vt material matrix = Total volume occupied by the material matrix,
E = Young’s modulus of the material as well as for fiber,
Ρ = Density of the material as well as for fiber,
G = Acceleration due to gravity.

10. COMPARISON OF ZYLON PROPERTIES WITH OTHER FIBERS:
FIBERS
TENSILE
STRENGTH (Gpa)
ELONGATION
%
MODULUS
(Gpa)
DENSITY
g/cm3
HEAT
RESISTANCE
In deg. C
ZYLON 5.8 3.5 180 1.54 650
STEEL
FIBER
2.8 1.8 200 7.8
POLYSTER 1.1 25 15 1.38 260

11. AL-MG EQUILIBRIUM DIAGRAM:

12. NEED FOR MAKING THE EUTECTIC (Al-Mg) ALLOY
The melting point of the fibre (zylon) is 650C and the temperature of the
alloy should not exceed 500C, if it does so then the fibre will undergo
thermal degradation.
According to the al-mg equilibrium diagram (shown in the previous slide) it
has been confirmed that the temperature of the eutectic alloy will not
exceed 500C.That is why this eutectic (al-mg) alloy has been selected.

14. MECHANICAL PROPERTIES:
ALUMINIUM
TEST CONDUCTED READING
YOUNG’ MODULUS (Gpa) 70
YIELD STRENGTH (Mpa) 18
ULTIMATE TENSILE STRENGTH (Mpa) 45
BRINELL HARDNESS 109.33

17. THANK YOU… 