DEVELOPMENT AND CHARACTERIZATION OF ALUMINIUM

BASE HYBRID METAL MATRIX COMPOSITE

PROJECT REPORT
PHASE I

Submitted to the
FACULTY OF MECHANICAL ENGINEERING
In partial fulfillment for the award of the degree
Of

BACHLOR OF ENGINEERING
IN
MECHANICAL ENGINEERING

By

DEPARTMENT OF MECHANICAL ENGINEERING

JSS ACEDMY OF TECHNICAL EDUCATION, NOIDA
ABDUL KALAM TECHNICAL UNIVERSITY

UTTAR PRADESH
 DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE

Certified that this Phase-I project titled, DEVELOPMENT AND CHARACTERIZATION OF

ALUMINIUM BASE HYBRID METAL MATRIX COMPOSITE is the bonafide work of Mr
Gaurav Ganganiya roll no 1409140906 who carried out the research under my supervision.
Certified further, that to the best of my knowledge the work reported here is does not form part of
any thesis or dissertation on the basis of which, a degree or award was conferred on an early
occasion on this or any other candidate.

Head of the Department Project Guide

Prof. , M.E., Mr Rajanna .L, M.E.,

(Assistant Professor)
Dept. of mechanical engineering Dept. of mechanical engineering
JSS ATEN NOIDA JSS ATEN, NOIDA

Submitted for the Project Viva-Voce examination held on.

Internal Examiner External Examiner

 ACKNOWLEDGEMENT

I wish to express my sincere gratitude to ----------------, The Principal, JSS ATEN

NOIDA, for providing me a golden opportunity to do this project.

I wish to record my immense appreciation and sincere thanks to my guide, .Prof.

Mr. RAJANNA. L Department of Mechanical Engineering, for selecting this project and
his hortatory and valuable guidance, encouragement and constructive criticisms at all
stages of this project

I sincerely thank Prof.P.K.JAYADEV, Professor and Head, Department of

Mechanical Engineering for this guidance, constant supervision, suggestion and showing
immense important to my project work.

I wish to thank my class advisor, Mr._________, Lecturer, Department of

Mechanical Engineering, for intellectual support, encouragement, and enthusiasm which
made this project possible.

I wish to take this opportunity to thank staff members of faculty of Mechanical

Engineering for their valuable suggestions and support Finally, I thank one and all those
who are rendering help directly and indirectly at various stages of this project.
 ABSTRACT

In the field of material science and engineering, there is a great impact ever
since the invention of composites materials. High strength and lightweight remain
the winning combination that propels composite materials into new arenas. The
composite materials replace conventional materials like steel, cast iron and
aluminum alloys by its superficial properties. As literatures were collected, it could
be found that metal matrix composites are under serious consideration as potential
candidate materials. To replace conventional materials in aerospace and automotive
applications. In this project, composites based on aluminum alloy (Al 7075)
reinforced with 10 % weight fraction of Aluminium Oxide or alumina (AL2O3)
and varing weight fraction (2%,4%,6%) of kynite powder in three trial is produced
by stir casting method. The Aluminium base metal matrix composite is tested in
order to find its properties .
 TABLE OF CONTENTS

CHAPTER TITLE PAGE NO

1. INTRODUCTION

1.1 OBJECTIVE

2. LITERATURE REVIEW

3. COMPOSITE MATERIALS

3.1 COMPOSITE MATERIALS

3.2 CLASSIFICATION OF COMPOSITES

3.2.1 Based on matrix

3.2.1.1 Polymer matrix composites

3.2.1.2 Ceramic matrix composites

3.2.1.3 Metal matrix composites

3.2.2 Based on material structure

3.2.2.1 Particulate composites

3.2.2.2 Fibrous composites

3.2.2.3 Laminate composites

3.3APPLICATION OF COMPOSITES

4. METAL MATRIX COMPOSITES

4.1CLASSIFICATION OF METAL MATRIX COMPOSITES

4.1.1 Particle reinforced composites

4.1.2 Whisker-reinforced composites

4.1.3 Continuous fiber-reinforced composites

4.2 PROCESSING OF METAL MATRIX COMPOSITES

4.2.1 Solid state processing

4.2.1.1 Diffusion bonding

 4.2.1.2 Sintering

4.2.2 Liquid state processing

4.2.2.1 Stir casting

4.2.2.2 Infiltration

4.2.3 In-situ fabrication

6. FABRICATION OF COMPOSITE

6.1 SELECTIONS OF MATERIALS AND COMPOSITION

6.1.1 Matrix material

6.1.2 Reinforcement materials

6.2 FABRICATION METHOD

7. CONCLUSION

8. APPENDICES

9. REFERNCES
 LIST OF TABLES

TABLE NO. TITLE PAGE NO

6.1 CHEMICAL COMPOSITION OF ALUMINIUM 7075

6.2 TYPICAL COMPOSITION OF ALUMINIUM 7075

 LIST OF FIGURES

FIGURE NO. TITLE PAGE NO

3.1. PARTICULATE COMPOSITE

3.2. REINFORCED COMPOSITE

3.3. REINFORCED COMPOSITE

5.1. TEST RESULTS

 NOMENCLATURE

ABBREVATION

Al203 Aluminium oxide

 CHAPTER 1

INTRODUCTION

In an advanced society like ours we all depend on composite materials in

some aspect of our lives. Fiber glass, developed in the late 1940s, was the first
modern composite and is still the most common. It makes up about 65 per cent of all
the composites produced today and is used for boat hulls, surfboards, sporting
goods, swimming pool linings, building panels and car bodies. Composites exist in
nature. A piece of wood is a composite, with long fibers of cellulose (a very complex
form of starch) held together by a much weaker substance called lignin. Cellulose is
also found in cotton and linen, but it is the binding power of the lignin that makes a
piece of timber much stronger than a bundle of cotton fibres. In engineering
materials, composites are formed by coatings, internal adhesives and laminating. An
important metal composite is clad metals. Thermostatic controls are made by roll-
bonding a high expansion alloy such as copper to a low expansion alloy like steel.
When the composite is heated it will deflect to open electrical contacts. Ply wood is
a similarly common composite. Since wood is weaker in its transverse direction than
its long direction, the alternating grain in plywood overcomes the transverse
deficiency.

Humans have been using composite materials for thousands of years. The
greatest advantage of composite materials is strength and stiffness combined with
lightness. In Modern aviation, both military and civil would be much less efficient
without composites. In fact, the demands made by that industry for materials that are
both light and strong has been the main force driving the development of
composites. The airframes of some smaller aircraft are made entirely from
composites, as are the wing, tail and body panels of large commercial aircraft.
Composites can be molded into complex shapes. Another advantage of composite
materials is that they provide design flexibility. Over recent decades many new
composites have been developed, some with very valuable properties. There are
varieties of composites that can be manufactured according to the requirements of
desired properties for a particular application.

Composites as a class of engineering materials provide almost unlimited

potential for higher strength, stiffness and corrosion resistance over pure material
systems of metals, ceramics and polymers. This will probably be the steels of the
next century.

Composite materials are formed by combining two or more materials that

have quite different properties. The different materials work together to give the
composite unique properties, but within the composite the materials can be
differentiated since they do not dissolve or blend into each other. Composites are
made up of two materials namely matrix and reinforcement. The matrix or binder
surrounds and binds together a cluster of fibres or fragments of the stronger material
(reinforcement).

In Metal Matrix Composites (MMCs), ceramics or metals in form of

fibres, whiskers or particles used to reinforce in a metal matrix. Most commonly
used matrixes are aluminum, magnesium, copper, titanium and zinc. The most
commonly used reinforcements are silicon carbide, alumina, boron, graphite and fly
ash. The strengthening effect of the reinforcements in composites depends on the
orientation of the reinforcements to the direction of the loads.
1.1OBJECTIVE

The objectives of this project are

To Development and characterization of Aluminium base Metal matrix

composites with the base metal as Aluminum 7075 reinforced with a weight
fraction of 10 % of Aluminium oxide or alumina (Al2O3) and varing weight
fraction(4%,6%,8%) of kynite powder by Stir casting method.
Performing tensile and hardness test and examine change in properties.
 CHAPTER 2

LITERATURE REVIEW

The Aluminum base metal matrix composites offer wide range of

properties suitable for a large number of engineering applications. Sufficient
literatures are available on different aspects of tribology and machining of
conventional metals and alloys but limited literature are available for reinforced
metal matrix composites.

Aluminum-Silicon (Al--Si) casting alloys are the most versatile of all

common foundry cast alloys in the production of pistons for automotive engines.
Depending on the Si concentration in weight percent, the Al--Si alloy systems fall
into three major categories: hypoeutectic (<12 wt % Si), eutectic (12-13 wt % Si)
and hypereutectic (14-25 wt % Si). However, commercial applications for
hypereutectic alloys are relatively limited because they are among the most difficult
Al alloys to cast and machine due to the high Si contents.

When high Si content is alloyed into Al, it adds a large amount of heat
capacity that must be removed from the alloy to solidify it during a casting
operation. Significant variation in the sizes of the primary Si particles can be found
between different regions of the cast article, resulting in a significant variation in the
mechanical properties for the cast article. The primary crystals of Si must be refined
in order to achieve hardness and good wear resistance. On the other hand, the usage
of hypoeutectic and eutectic alloys are very popular for the industry, because they
are more economical to produce by casting, simpler to control the cast parameters,
and easier to machine than hypereutectic. However, most of them are not suitable for
high temperature applications, such as in the automotive field, for the reason that
their mechanical properties, such as tensile strength, are not as high as desired in the
temperature range of 500 F.-700 F. Current state-of-the-art hypoeutectic and
eutectic alloys are intended for applications at temperatures of not higher than about
450 F. The undesirable microstructure and phase transformation results in
drastically reduced mechanical properties, more particularly the ultimate tensile
strength and high cycle fatigue strengths, for hypoeutectic and eutectic Al--Si alloys.

One approach taken by the art is to use ceramic fibres or ceramic

particulates to increase the strength of hypoeutectic and eutectic Al--Si alloys. This
approach is known as the aluminum Metal Matrix Composites (MMC) technology.
For example, R. Bowles has used ceramic fibres to improve tensile strength of a
hypoeutectic 332.0 alloy, in a paper entitled, "Metal Matrix Composites Aid Piston
Manufacture," Manufacturing Engineering, May 1987.

Moreover, A. Shakesheff has used ceramic particulate for reinforcing

another type of hypoeutectic A359 alloy, as described in "Elevated Temperature
Performance of Particulate Reinforced Aluminum Alloys," Materials Science Forum,
Vol. 217-222, pp. 1133-1138 (1996).

In a similar approach, cast aluminum MMC for pistons using eutectic

alloy such as the 413.0 type, has been described by P. Rohatgi in a paper entitled,
"Cast Aluminum Matrix Composites for Automotive Applications," Journal of
Metals, April 1991.

Vikram Singh and R.C. Prasad has fabricated and analyzed the tensile and
fracture behavior of 6061 Al-SiCp metal matrix Composite by reinforcing with 5%,
10% and 15 volume % SiC particles. Vidya Sagar Avadutala has analyzed the cracks
in composite materials (aluminum and low carbon steel) using Ansys.
 CHAPTER 3

COMPOSITE MATERIALS

3.1 COMPOSITE MATERIALS

Composite material is a material composed of two or more distinct

phases (matrix phase and dispersed phase) and having bulk properties significantly
different from those of any of the constituents.

Matrix phase is the primary phase having a continuous character. Matrix

is usually more ductile and is a less hard phase. It holds the dispersed phase and
shares a load with it.

The second phase (or phases) is embedded in the matrix in a

discontinuous form. This secondary phase is called dispersed phase. Dispersed phase
is usually stronger than the matrix, therefore it is sometimes called reinforcing
phase.

Many of common materials (metal alloys, doped Ceramics and Polymers

mixed with additives) also have a small amount of dispersed phases in their
structures, however they are not considered as composite materials since their
properties are similar to those of their base constituents.
3.2 CLASSIFICATION OF COMPOSITES

There are two classification systems of composite materials. One of them

is based on the matrix material and the second is based on the material structure.

3.2.1 BASED ON MATRIX

One commonly used classification of composites is based on matrix used

based on the base matrix composites can be divided into three main groups:

I. Polymer Matrix Composites (PMCs)

II. Ceramic Matrix Composites (CMCs)
III. Metal Matrix Composites (MMCs)

3.2.1.1 POLYMER MATRIX COMPOSITES

Polymer Matrix Composite (PMC) is material consisting of polymer

(resin) matrix combined with a fibrous reinforcing dispersed phase. Polymer Matrix
Composites are very popular due to their low cost and simple fabrication methods.
Use of non-reinforced polymers as structure materials is limited by low level of their
mechanical properties. For example the tensile strength of one of the strongest
polymers - epoxy resin is 20000 psi (140 MPa). In addition to relatively low
strength, polymer materials possess low impact resistance. Two types of polymers
are used as matrix materials for fabrication composites. Thermosets (epoxies,
phenolics) and Thermoplastics (Low Density Polyethylene (LDPE), High Density
Polyethylene (HDPE), polypropylene, nylon, acrylics).
 According to the reinforcement material, the groups of Polymer Matrix
Composites (PMC) used are Fibreglasses, Carbon Fibres, and Kevlar. Reinforcing
fibres may be arranged in the form of Unidirectional fibres, Ravings, Veil mat,
Chopped strands, Woven fabric.

3.2.1.2 CERAMIC MATRIX COMPOSITES

Ceramic Matrix Composite (CMC) is material consisting of a ceramic

matrix combined with a ceramic (oxides, carbides) dispersed phase. Ceramic Matrix
Composites are designed to improve toughness of conventional ceramics, the main
disadvantage of which is brittleness. Ceramic Matrix Composites are reinforced by
either continuous (long) fibres or discontinuous (short) fibres. These composites are
mainly used for high temperature applications and in electronic industries.

3.2.1.3 METAL MATRIX COMPOSITES

Metal Matrix Composite (MMC) is material consisting of a metallic

matrix combined with a ceramic (oxides, carbides) or metallic (lead, tungsten,
molybdenum) dispersed phase. Most commonly used matrixes are aluminium,
magnesium, copper, titanium and zinc. The most commonly used reinforcements are
silicon carbide, alumina, boron, graphite and fly ash. Development of these materials
is a subject of great interest as they offer attractive combination of physical and
mechanical properties, which cannot be obtained in monolithic alloys.

3.2.2 BASED ON MATERIAL STRUCTURE

Based on the material structure composites are classified into

1. Particulate composites
2. Fibrous composites
3. Laminate composites

3.2.2.1 PARTICULATE COMPOSITES

 Particulate Composites consist of a matrix reinforced by a dispersed
phase in form of particles.

Figure 3.1 Particulate Composite

These particles are sometimes divided into two subclasses:

a) Composites with random orientation of particles.

It is a structure filled with one or more additional materials.
b) Composites with preferred orientation of particles.
Dispersed phase of these materials consists of two-dimensional flat platelets
(flakes), laid parallel to each other.

Effect of the dispersed particles on the composite properties depends on

the particles dimensions. Very small particles (less than 0.25 micron in diameter)
finely distributed in the matrix impede movement of dislocations and deformation of
the material. Such strengthening effect is similar to the precipitation hardening. In
contrast to the precipitation hardening, which disappears at elevated temperatures
when the precipitated particles dissolve in the matrix, dispersed phase of particulate
composites (ceramic particles) is usually stable at high temperatures, so the
strengthening effect is retained. Many of composite materials are designed to work
in high temperature applications. Large dispersed phase particles have low
strengthening effect but they are capable to share load applied to the material,
resulting in increase of stiffness and decrease of ductility. Hard particles dispersed in
a softer matrix increase wear and abrasion resistance. Soft dispersed particles in a
harder matrix improve machinability (lead particles in steel or copper matrix) and
reduce coefficient of friction (tin in aluminium matrix or lead in copper matrix).

3.2.2.2 FIBROUS COMPOSITES

They are composed of reinforced fibres in matrix. They are further

classified as Short fibres and long-fibres reinforced composites.

1. Short-fibres reinforced composites:

Short-fibres reinforced composites consist of a matrix reinforced by a

dispersed phase in form of discontinuous fibres (length < 100*diameter).

Figure 3.2 Short Fibres Reinforced Composite

1. Composites with random orientation of fibres.

2. Composites with preferred orientation of fibres.

2. Long-fibres reinforced composites:

 Long-fibres reinforced composites consist of a matrix reinforced by a
dispersed phase in form of continuous fibres.

Figure 3.3 Long Fibres Reinforced Composite

1. Unidirectional orientation of fibres.

2. Bidirectional orientation of fibres (woven).

The length of a fiber affects the properties of the composites and also its
processing characteristics. Generally continuous fibres are easier to handle than
short fibres. The fiber reinforced composites are of interest in aerospace applications
where weight saving is of great importance

3.2.2.3 LAMINATE COMPOSITES

Laminate composites consist of layers with different anisotropic

orientations or of a matrix reinforced with a dispersed phase in form of sheets.

When a fibres reinforced composite consists of several layers with

different fibres orientations, it is called multilayer (angle-ply) composite.

Laminate composites provide increased mechanical strength in two

directions and only in one direction, perpendicular to the preferred orientations of
the fibres or sheet, mechanical properties of the material are low. The best example
of laminar composite is plywood.

3.3 APPLICATION OF COMPOSITES

Hybrid materials and composites form the key to successful development

of next-generation aerospace propulsion and power systems. Metal-matrix
composites play a significant role in the development of future aerospace
components. These materials are not only resistant to high temperatures, but also
provide significant improvements in weight specific mechanical and thermal
properties.

Aluminum is the most attractive non-ferrous matrix material extensively

used particularly in the aerospace industry where weight of structural components is
crucial .The low density and high specific mechanical properties of aluminum metal
matrix composites (MMC) make these alloys one of the most interesting material
alternatives for the manufacture of lightweight parts for many types of vehicles.
With wear resistance and strength equal to cast-iron, 67% lower density and three
times the thermal conductivity, aluminum MMC alloys are ideal materials for the
manufacture of lightweight automotive and other commercial parts. The majority of
effort in aluminum matrix composites has been directed toward development of high
performance composites, with very high strengths and module, for use in specialized
aerospace applications. However, there are a number of other applications in aircraft
engines and aerospace structures where these very high properties may not be
required, and where it could be cost effective to use other metal matrix composites.
For example cost, weight, and stiffness-critical components, such as engine static
structures, do not require the very high directional properties available with
composites reinforced with aligned continuous fibres. For these reasons, efforts were
initiated to assess the potential of applying low cost aluminum matrix composites to
these structures, using low-cost reinforcements and low-cost composite fabrication
processes, including powder metallurgy, direct casting, and hot molding techniques.

Cryogenically processed automobile components like brake rotors, gears,

piston, connecting rods, engines and machine parts, tools and gun barrels show
significant extension in the performance and productive life. The metallurgy behind
cryogenic processing is that it creates a large amount of fine or small carbides that
precipitate uniformly throughout the lattice structure, closes and refines grain
structures. Treated piston rings seal better against treated cylinder walls reducing
blow-by and increasing horsepower. Cylinder blocks do not distort and cylinder
bores stay straight and smooth when subjected to heat and vibration.

Application of Al 7075 Composites to Aircraft Engine and Aerospace Structures

 Studies show that these low cost Al matrix composites demonstrated a
good potential for application to aerospace structures and aircraft engine
components. The composites are formable with normal aluminum metal-working
techniques and equipment at warm working temperatures. They can also be made
directly into structural shapes during fabrication.

These composites merit additional work to determine fatigue, long-term

stability, and thermal cycle behavior to characterize more fully their properties and
allow their consideration for structural design for a variety of aircraft and spacecraft
applications.

The most significant aspect of these data was the increase in modulus
over that of competitive aluminum alloys. At 20 % vol reinforcement, the modulus
of SiC/Al composites was about 50% above that of aluminum and approached that
of titanium. This increase in modulus was achieved with a material having a density
one-third less than that of titanium. Comparison of the properties of the various
composites shows that the modulus/density ratio of 20 vol % SiC/Al composites was
about 50% greater than that of Al or Ti alloys, while at 30 vol % SiC the advantage
was increased to about 70% and at 40 vol % SiC the modulus was almost double that
of unreinforced Al or Ti structural alloys

CHAPTER 4

METAL MATRIX COMPOSITES

 Strength is maximum. Properties of the matrix and the composition of the
Conventional monolithic materials have limitations in terms of achievable
combinations of strength, stiffness, coefficient of expansion and density. MMCs
have emerged as an important class of advanced materials giving engineers the
opportunity to tailor the material properties according to their needs. A Metal matrix
composite is an engineered combination of two or more materials (one of which is a
metal) in which tailored properties are achieved by systematic combination of
different constituents. MMC's desirable properties result from the presence of small,
high strength ceramic particles, whiskers or fibres uniformly distributed throughout
the aluminum alloy matrix. Aluminum MMC castings are economically competitive
with iron and steel castings in many cases. However the presence of these wear
resistant particles significantly reduces the machinability of the alloys, making
machining costs higher due mainly to increased tool wear. As a result, the
application of cast MMCs to components requiring a large amount of secondary
machining has been somewhat stifled.

Development of these materials is a subject of great interest as they offer

attractive combination of physical and mechanical properties, which cannot be
obtained in monolithic alloys. Essentially, these materials differ from the
conventional engineering materials from the point of homogeneity.

The major advantages of MMCs compared to unreinforced materials are as follows:-

Higher strength-to-density ratios

 Higher stiffness-to-density ratios

Better fatigue resistance

Better elevated temperature properties

Lower coefficients of thermal expansion

Improved abrasion and wear resistance

Improved damping capabilities

4.1 CLASSIFICATION OF METAL MATRIX COMPOSITES

Classifications of MMCs based on reinforcement are

Particle reinforced composites

Whisker reinforced composites

Continuous fiber-reinforced composites

These classes are briefly discussed in the following sections,

4.1.1 PARTICLE REINFORCED COMPOSITES

Particulate composites consist of one or more materials suspended in a

metal matrix. These composites generally contain ceramic reinforcements with an
aspect ratio less than 5. Ceramic reinforcements used are generally Al 2O3, SiCp or
Gr and present normally in volume fraction less than 30 % when used for structural
and wear resistance applications. Mechanical properties of PMMCs are inferior
compared to whisker/fiber reinforced MMCs but far superior compared to
unreinforced alloys. These composites are near isotropic in nature and can be
subjected to forming operations like extrusion, rolling and forging.

4.1.2 WHISKER-REINFORCED COMPOSITES

 Whiskers are generally very short and stubby although the length-to-
diameter ratio can vary from 20 to 200. Whisker is more perfect than a fiber and
hence exhibits even better properties. Whiskers are obtained by crystallization on a
very small scale resulting in a nearly perfect alignment of crystals. Short alumina
fiber reinforced aluminium matrix composites is one of the first and most popular
MMCs to be developed and used in automobile pistons. Mechanical properties of
whisker reinforced composites are superior when compared to particle reinforced
composites. Whiskers can be incorporated into the composites by various
techniques like powder metallurgy and casting techniques to produce metal/whisker
systems.

4.1.3 CONTINUOUS FIBER-REINFORCED COMPOSITES

In fibre reinforced composite materials, the fibre orientation decides the

strength of the composite and the direction in which the matrix and the properties of
the fibre are other factors which influence the performance of the fibre-reinforced
composites. Fibre reinforced composites are produced from a wide range of
constituent materials. The length of a fibre affects the properties of the composites
and also its processing characteristics. Generally continuous fibres are easier to
handle than short fibres. The fibre reinforced composites are of interest in aerospace
applications where weight saving is of great importance.

4.2 PROCESSING OF METAL MATRIX COMPOSITES

Fabrication methods are important part of the design process for all
structural materials including MMCs. Considerable work is under way in this critical
area. Different manufacturing techniques are used to fabricate the metal matrix
composites. They can be classified into,

Solid state processing

Liquid state processing
In-situ processing

The different processing routes for MMCs are briefly discussed in the following
sections.

4.2.1 SOLID STATE PROCESSING

Solid state fabrication of Metal Matrix Composites is a of process, in

which Metal Matrix Composites are formed as a result of bonding matrix metal and
dispersed phase due to mutual diffusion occurring between them in solid states at
elevated temperature and under pressure. Low temperature of solid state fabrication
process (as compared to Liquid state fabrication of Metal Matrix Composites)
depresses undesirable reactions on the boundary between the matrix and dispersed
(reinforcing) phases.

There are two principal groups of solid state fabrication of Metal Matrix
Composites:

1. Diffusion bonding
2. Sintering.

4.2.1.1 DIFFUSION BONDING

 Diffusion Bonding is a solid state fabrication method, in which matrix in
form of foils and dispersed phase in form of layers of long fibres are stacked in a
particular order and then pressed at elevated temperature.

The finished laminate composite material has a multilayer structure.

Application of pressure and temperature either by hot or cold pressing provides good
bonding between the fibre and the matrix in the perform. This improves the strength
of the composites by introduction of plastic deformation in matrix and removing
voids to densify the composite fully Diffusion Bonding is used for fabrication of
simple shape parts (plates, tubes).

4.2.1.2 SINTERING

Sintering fabrication of Metal Matrix Composites is a process, in which a

powder of a matrix metal is mixed with a powder of dispersed phase in form of
particles or short fibres for subsequent compacting and sintering in solid state
(sometimes with some presence of liquid).

Sintering is the method involving consolidation of powder grains by

heating the green compact part to a high temperature below the melting point,
when the material of the separate particles diffuse to the neighbouring powder
particles.

In contrast to the liquid state fabrication of Metal Matrix Composites,

sintering method allows obtaining materials containing up to 50% of dispersed
phase.

Metal Matrix Composites may be deformed also after sintering operation

by rolling, forging, and pressing, Drawing or Extrusion. The deformation operation
may be either cold (below the recrystallization temperature) or hot (above the
recrystallyzation temperature).

Deformation of sintered composite materials with dispersed phase in

form of short fibres results in a preferred orientation of the fibres and anisotropy of
the material properties (enhanced strength along the fibres orientation).

4.2.2 LIQUID STATE PROCESSING

Liquid state fabrication of Metal Matrix Composites involves

incorporation of dispersed phase into a molten matrix metal, followed by its
Solidification.

In order to provide high level of mechanical properties of the composite,

good interfacial bonding (wetting) between the dispersed phase and the liquid matrix
should be obtained.

Wetting improvement may be achieved by coating the dispersed phase

particles (fibres). Proper coating not only reduces interfacial energy, but also
prevents chemical interaction between the dispersed phase and the matrix.

The techniques used for producing cast particulate composites using

liquid metallurgy are Stir casting and Infiltration process

4.2.2.1 STIR CASTING

The simplest and the most cost effective method of liquid state
fabrication is Stir Casting.
 Stir Casting is a liquid state method of composite materials fabrication,
in which a dispersed phase (ceramic particles, short fibres) is mixed with a molten
matrix metal by means of mechanical stirring.

The liquid composite material is then cast by conventional casting

methods and may also be processed by conventional Metal forming technologies.

Stir Casting is characterized by the 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:

1. There are local clouds (clusters) of the dispersed particles (fibres);

2. There may be gravity segregation of the dispersed phase due to a difference in the
densities of the dispersed and matrix phase.

The technology is relatively simple and low cost.

Distribution of dispersed phase may be improved if the matrix is in semi-solid

condition.

The method using stirring metal composite materials in semi-solid state is

called Rheocasting. High viscosity of the semi-solid matrix material enables better
mixing of the dispersed phase.

4.2.2.2 INFILTRATION

Infiltration is a liquid state method of composite materials fabrication, in

which a preformed dispersed phase (ceramic particles, fibres, woven) is soaked in a
molten matrix metal, which fills the space between the dispersed phase inclusions.
 The motive force of an infiltration process may be either capillary force
of the dispersed phase (spontaneous infiltration) or an external pressure (gaseous,
mechanical, electromagnetic, centrifugal or ultrasonic) applied to the liquid matrix
phase (forced infiltration).

Gas pressure infiltration

Gas Pressure Infiltration is a forced infiltration method of liquid phase

fabrication of Metal Matrix Composites, using a pressurized gas for applying
pressure on the molten metal and forcing it to penetrate into a preformed dispersed
phase. Gas Pressure Infiltration method is used for manufacturing large composite
parts.

The method allows using non-coated fibres due to short contact time of the
fibres with the hot metal.In contrast to the methods using mechanical force, Gas
Pressure Infiltration results in low damage of the fibres.

Squeeze casting infiltration

Squeeze Casting Infiltration is a forced infiltration method of liquid

phase fabrication of Metal Matrix Composites, using a movable mold part (ram) for
applying pressure on the molten metal and forcing it to penetrate into a performed
dispersed phase, placed into the lower fixed mold part.

Squeeze Casting Infiltration method is similar to the Squeeze casting

technique used for metal alloys casting.
Squeeze Casting Infiltration process has the following steps:

A perform of dispersed phase (particles, fibres) is placed into the lower fixed
mold half.

A molten metal in a predetermined amount is poured into the lower mold half.

The upper movable mold half (ram) moves downwards and forces the liquid
metal to infiltrate the pre form.

The infiltrated material solidifies under the pressure.

The part is removed from the mold by means of the ejector pin.

The method is used for manufacturing simple small parts (automotive engine pistons
from aluminum alloy reinforced by alumina short fibres).

Pressure die infiltration

Pressure Die Infiltration is a forced infiltration method of liquid phase

fabrication of Metal Matrix Composites, using a Die casting technology, when a
preformed dispersed phase (particles, fibres) is placed into a die (mould) which is
then filled with a molten metal entering the die through a sprue and penetrating into
the pre form under the pressure of a movable piston (plunger).
4.2.3 IN-SITU FABRICATION

In situ fabrication of Metal Matrix Composite is a process, in which

dispersed (reinforcing) phase is formed in the matrix as a result of precipitation from
the melt during its cooling and Solidification.

Different types of Metal Matrix Composites may be prepared by in situ

fabrication method:

1. Particulate in situ MMC Particulate composite reinforced by in situ

synthesized dispersed phase in form of particles.

Examples: Aluminum matrix reinforced by titanium boride (TiB 2) particles,

magnesium matrix reinforced by Mg2Si particles.

2. Short-fibre reinforced in situ MMC Short-fibre composite reinforced by in

situ synthesized dispersed phase in form of short fibres or whiskers (single crystals
grown in form of short fibres).

Examples: Titanium matrix reinforced by titanium boride (TiB2) whiskers,

Aluminum matrix reinforced by titanium aluminide (TiAl3) whiskers.

3. Long-fibre reinforced in situ MMC Long-fibre composite reinforced by in situ

synthesized dispersed phase in form of continuous fibres.

Example: Nickel-aluminum (NiAl) matrix reinforced by long continuous fibres of

Mo (NiAl-9Mo alloy).

Dispersed phases of in situ fabricated Metal Matrix Composites may

consist of intermetallic compounds, carbides, borides, oxides, one of eutectic
ingredients.
Advantages of in situ Metal Matrix Composites:

In situ synthesized particles and fibres are smaller than those in materials with
separate fabrication of dispersed phase (ex-situ MMCs). Fine particles provide
better strengthening effect;

In situ fabrication provides more homogeneous distribution of the dispersed

phase particles;

Bonding (adhesion) between the particles of in situ formed dispersed phase

and the matrix is better than in ex-situ MMCs;

Equipment and technologies for in situ fabrication of MMCs are less

expensive.

Disadvantages of in situ Metal Matrix Composites:

Choice of the dispersed phases is limited by thermodynamic ability of their

precipitation in particular matrix;

The size of dispersed phase particles is determined by solidification conditions

CHAPTER 5

CRACKS

A crack is a type of fracture that separates a solid body into two, or more, pieces
under the action of stress. There are three types of modes of failure [4].

Mode I: The forces are perpendicular to the crack (the crack is horizontal and the
forces are vertical), pulling the crack open. This is referred to as the opening mode.
Mode II: The forces are parallel to the crack. One force is pushing the top half of the
crack back and the other is pulling the bottom half of the crack forward, both along
the same line. This creates a shear crack: the crack is sliding along itself. It is called
in-plane shear because the forces are not causing the material to move out of its
original plane.

Mode III: The forces are perpendicular to the crack (the crack is in front-back
direction, the forces are pulling left and right). This causes the material to separate
and slide along itself, moving out of its original plane (which is why its called
out-of-plane shear).

Figure 5.1 Three Loading Modes

CHAPTER 6

FABRICATION OF COMPOSITES

6.1 SELECTION OF MATERIALS AND COMPOSITION

The base metal is chosen as Aluminum 7075.

 The reinforcement is chosen as aluminum oxide Al2O3 (powder) and Kynite
With the base metal as Aluminium, the composite is to be fabricated with 10%
weight fraction of Aluminum Oxide Al2O3 (powder) and varying weight
fraction (4%,6%,8% ) of kynite in each trial.

6.1.1 Matrix material

Aluminium, the second most abundant metallic element on the earth,

became an economic competitor in engineering applications recently. The metal
matrix selected for present investigation is Al 7075 . The chemical composition of
the matrix material is as shown the Table.

Table 6.1 Chemical Composition of Al 7075 (weight %)

Element Si Fe Cu Mn Mg Zn Ti V Zr Al
Nominal 0.50 0.50 3.8 to 0.30 1.20 0.25 0.15 0.15 0.15 Balance
Composition max max 7.90 to to max max max max
% ( Weight) 0.90 1.80
 Actual 0.24 0.20 4.43 0.47 1.32 0.07 0.22 0.01 0.01 Balance
Comp%
(Weight)

The typical Composition of the matrix material is shown in the following table.

Table 6.2 Typical Composition of Al 7075 (weight %)

Element Weight in %

Al 93.50

Cu 4.4

Mg 1.5

Mn 0.6

This matrix was chosen since it provides excellent combination of strength

and damage tolerance at high strength applications like structural components and
high strength elements. It also has a high heat dissipation capacity due to its high
thermal conductivity.

6.1.2 REINFORCEMENT MATERIALS

Aluminium Oxide or Alumina (Al2O3) particles are the most commonly

used reinforcement materials in the discontinuously reinforced metal-matrix
composite system. Aluminum matrix composites reinforced with Aluminium Oxide
particulates provide for a low-cost, high-modulus material that can be processed via
conventional powder metallurgy techniques. With increased additions of
Aluminium Oxide reinforcement, the modulus increases, and losses in strength,
ductility, and toughness may occur. Also, the role of the interfacial bond between
Aluminium Oxide particulates and the aluminum matrix may further detract from
the mechanical properties when the composite is subjected to high temperatures.
Particle size and shape are important factors in determining materials properties.
Fatigue strength is greatly improved with the use of fine particles.

The Aluminium Oxide particles, which were used to fabricate

the composite, had an average particle size of 25 m and average density of 1.95 g /
cm3. The melting point of the Aluminium Oxide is 2890 0C. The Kynite particles
used for hybrid composites are of 25 m size and average density of 2.11 g / cm3. It
is a hard material with a hardness of 1-2 Mohrs scale, with a melting point of 3650 0
C. Graphite is a natural lubricant used in many applications.

6.2 FABICATION METHOD

Since the Al 7075 is found in bulk quantities in the market it is proposed to

first fabricate the Al 7075 metal by using the typical composition as shown in the
table 5.2. The materials are displayed in photographs below.

STIR CASTING

The stir casting technique was used to fabricate the composite specimen
as it ensures a more uniform distribution of the reinforcing particles. This method is
most economical to fabricate composites with discontinuous fibers or particulates. In
this process, matrix alloy (Al 7075) was first superheated above its melting
temperature and then temperature is lowered gradually below the liquidus
temperature to keep the matrix alloy in the semisolid state. At this temperature, the
preheated Aluminium Oxide particles of 10 % (by weight) and kynite particle of
average size of 25 m and 25 m respectively were introduced into the slurry and
mixed using a graphite stirrer.

The composite slurry temperature was increased to fully liquid state and
automatic stirring was continued to about five minutes at an average stirring speed of
300-350 rpm under protected organ gas. The Aluminium Oxide particles help in
distributing the kynite particles uniformly throughout the matrix alloy. The melt was
then superheated above liquidus temperature and finally poured into the cast iron
permanent mould for testing specimen. The specification of the fabricated billet
composite is accordind to ASTM E8 which is 100 mm length and 10 mm width and a
thickness of 6 mm

CHAPTER 7

CONCLUSION

The relevant materials and the selection criteria have been collected and
identified. The type of crack and material properties have been studied in phase I.

In the phase-II project, the composite metal is fabricated, and the tests had
perfomed, the analysis of the fabricated composite with is studied and the out

come will be the solution for different applications of the composite material
in the field of aerospace and automotive industries.
CHAPTER 8

APPENDICES
 CHAPTER 9

REFERENCES

Text Books

1. Abis, S., (1989), Characteristics of an aluminium alloy/Alumina Metal

Matrix composite, Composites science and technology, Vol.35, pp.1-11.
 2. Brian Terry and Jones Glyn.,(1990), Metal matrix composite, Elsevier
Science Publishers Ltd., England, pp.41-47.
3. ASM International, (1993),
Advanced Materials and Processes, Vol.143 No.6, p.21.
4. American Foundry mens Society, Cast metals handbook, 4th ed., Desplaines
(1957).
5. J.J. Sha, J.S. Park, T. Hinoki and A. Kohyama, Tensile behavior and
microstructural characterization of SiC fibres under loading, Materials
Science and Engineering: A, Volume 456, Issues 1-2, 15 May 2007, Pages
72-77.

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