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FABRICATION OF HIGH PERFORMANCE POWDER-

METALLURGY ALUMINUM MATRIX COMPOSITES
a
H.J. Rack
a
Materials Engineering Activity Department of Mechanical Engineering , Clemson University ,
Clemson, South Carolina, 29634-0921
Published online: 27 Apr 2007.

To cite this article: H.J. Rack (1988) FABRICATION OF HIGH PERFORMANCE POWDER-METALLURGY ALUMINUM MATRIX
COMPOSITES, Advanced Materials and Manufacturing Processes, 3:3, 327-358, DOI: 10.1080/08842588708953210

To link to this article: http://dx.doi.org/10.1080/08842588708953210

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 ADV. MATERIALS & MANUFACTURING PROCESSES, 3(3), 327-358 (1988)

FABRICATION OF HIGH PERFORMANCE POWDER·METALLURGY

ALUMINUM MATRIX COMPOSITES

H. J. Rack
Materials Engineering Activity
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Department ofMechanical Engineering

Clemson University
Clemson, South Carolina 29634-0921

ABSTRACT

Recent years have seen the development of a wide range of

high-performance discontinuously reinforced aluminum powder metal-
lurgy composites. These materials have combined both standard
wrought, e.g., 6061 and 2124, and specialty matrix compositions,
e.g., Al-Cu-Mg-Li and Al-Fe-Ce, with a wide variety of discontin-
uous reinforcements, e.g., A1203, B4C, SiC p and SiC w' This paper
discusses the manufacturing procedures utilized to fabricate these
light-weight powder-metallurgy composites. Emphasis is given to
developing a generalized framework for understanding the inter-
relationship existing between thermo~mechanical treatment and the
mechanical behavior of these composite systems.

INTRODUCTION

Modern design procedures continually strive to increase struc-

tural efficiencies through reductions in either absolute weight or
increases in the strength-to-weight ratio. Figure 1 illustrates
how, for a cargo-bomber aircraft application (1), reductions in
material density, or increases in modulus (stiffness), yield
strength and/or ultimate tensile strength, can be directly transla-
ted to reductions in structural weight. For example, a 10 percent

327

Copyright © 1988 by Marcel Dekker. Inc.

 328 RACK

24
22
20
18
E
16
~
0~ 14

• 12.
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8
6
4
2
_____-+-----Fcy
O-f"=;I-:--+----.,I-:-+----.,I-:-+---+-+---+-_f_
o 10 20 30 40 50' 60 70 80 90 100
.. % Properly Chonge

FIG. 1 - Performance Enhancement Related Structural Weight

Reductions in Cargo-Bomber Aircraft Applications (1).

reduction in alloy density, which can be achieved through substitu-

tion of AI-Li alloys for 2000 series aluminum alloys, will result
in a 10 percent reduction in structural weight. Alternatively, a
50 percent increase in modulus, which can be achieved through
substitution of a discontinuous silicon carbide (SiC) reinforced
alloy for an unreinforced wrought aluminum alloy, will also result
in a 10 percent reduction in structural weight (2). Indeed, it is
possible to envision combining these effects thru the development
of a reinforced AI-Li alloy (3-7).
System trade-studies, such as outlined above, have been the
primary motivating factor in the renewed interest shown in metal
matrix composites. Initially, these investigations focused on
continuous fiber reinforced metal matrix composites. Wide spread
industrial application of these composites has however been
limited by the high costs of the reinforcement fiber, e.g.,
$300/1b for B, and the metal matrix component fabrication process.
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 329

,
Ceramic Reinforcement

Deagglomeration

Metal Powder ----------------~

•,
Mixing

,
Billet Consolidation

,
Homogenization

,
Scalping
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Inspection

FIG. 2 - Powder-Ceramic Reinforcement Blending Sequence for

Discontinuously Reinforced Metal Matrix Composites.

Most recent attention has therefore been directed towards commer-

cialization of discontinuously reinforced metal matrix composites,
notably silicon carbide particulate and whisker reinforced
aluminum alloys, where low fiber costs, $2-20/lb, can be combined
with standard or near-standard metal working practices. This paper
discusses the manufacturing procedures used to fabricate discontin-
uously reinforced aluminum metal matrix composites. It further
considers how alloy chemistry and processing modifications are
being utilized to enhance their mechanical performance.

Billet Fabrication

Two principal methods are currently being employed to

fabricate discontinuously reinforced powder-metallurgy metal
matrix composite billets. A generalized flow chart illustrating
the first of these is presented in Figure 2.
The initial step in the manufacturing sequence depicted in
Figure 2 involves proper selection of the discontinuous ceramic
 330 RACK

TABLE 1
PROPERTIES OF SELECTED CERAMIC REINFORCEMENTS (8, 51)

Ceramic Coefficient Strength Elastic Modulus

of Expansion (ksi) (mpsi)
(l0-6/oF)

BeO 4.1 3.5(ZOOOoF) 27.5(2000 oF)

MgO 6.45 6.0(2000 oF) ZZ.0(2000oF)
Th02 5.3 Z8.0(2000oF) Z9.0(ZOOOoF)
UOZ 5.3 25.0(ZOOOoF)
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ZrOZ 6.67 1Z.0(2000oF) 19.2(2000 oF)

Ce02 6.9 85.4(75°F) 26.8(75°F)
AIZ03 4.4 32.0(ZOOOoF) 55.0(2000 oF)
TaSi2 6.0 49.0(Z300oF)
MoSiZ 4.85 40.0(ZOOOoF) 40.0(Z300oF)
WSi2 5.0 36.0(ZOOOoF)
TiBZ 4.6 60.0(ZOOO°F)
ZrBZ 4.5 73.0(75 0 F)
TiC 4.22 8.0(ZOOOoF) 39.0(75°F)
ZrC 3.7 13.0(2000 oF) 52.0(75°F)
HfC 3.7 46.0(75°F)
VC 3.98 63.0(75°F)
NbC 3.8 49.0(75°F)
TaC 3.59 53.0(75°F)
MoZC 3.Z3 33.0(75°F)
WC Z.83 97.0(75°F)
B4C 3.38 400.0(75°F) 65.0(75°F)
SiC 3.00 1Z10.0(75°F) 47.0(ZOOOoF)
AIN 2.69 300.0(75°F) 45.0(2000 oF)

reinforcement and the matrix alloy. Selection criteria for the

ceramic reinforcement include:
- elastic modulus
- tensile strength
- density
- melting temperature
- thermal stability
- compatibility with matrix
- thermal coefficient of expansion
- size and shape
- cost
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 331

Table 1 summarizes selected properties for a wide range of

possible discontinuous ceramic reinforcements. Unfortunately much
of the available information is for a rather narrow temperature
range. This is of major importance if the composite system is to
operate at elevated temperature.
Elastic moduli, tensile strengths and densities are of
particular interest in establishing the eventual structural
efficiencies of the discontinuously reinforced metal matrix
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composites. Chemical stability of the ceramic reinforcement,

including its compatibility with a suggested matrix, is of
importance for both end-use and composite fabrication. For
example, the matrix composition of continuous fiber FP A1203
reinforced Al must be adjusted to enhance fiber wettability since
Al does not wet A1203' This is conventionally done thru the
addition of Li to the Al alloy matrix (9). However, this reaction
must be limited, i.e., enough to wet the fiber to promote bonding,
without reinforcement degradation either during composite
fabrication or utilization.
A consideration of the thermal mismatch between the proposed
reinforcement and matrix is essential if the composite will be
subject to thermal cycling, for example, as might occur in an
internal combustion engine. The strain, t, developed at the
interface of a discontinuously reinforced metal matrix composite
due to a single thermal cycle is:
t = ha hT
where ha is the difference between the thermal coefficients of
expansion for the reinforcement and the matrix, and hT is the
range of temperature experienced during a thermal excursion. In
order to minimize strain accumulation, differences in expansion
coefficients between reinforcement and matrix should be minimized.
It is also important to recognize that relaxation of these
strains, by the formation of a dislocation network, will alter the
response of a discontinuously reinforced metal matrix composite to
thermo-mechanical processing from that experienced by an unrein-
forced alloy (10-13).
 332 RACK
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FIG. 3 - Scanning Electron Micrographs of Discontinuous SiC

Reinforcements (a) ACMC Whiskers, (b) AMMATRIX Whiskers,
(c) Tokai Whiskers, (d) AMMATRIX Oblate Platelets, and
(e) Particulates.
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 333
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FIG. 4 - Scanning Electron Micrographs of Discontinuous (a) Si3N4

Whiskers, (b) Fine B4C Particulates, (c) Coarse B4C
Particulates, (d) TiB2 Particulates, (e) Saffil A1203
Fiber, (f) Kaowool AI203-Si02, (g) Y203 Fiber, (h) Ce02
Fiber, (i) Zr02 Fiber, and (j) Hf02 Fiber. (continued)

Scanning electron micrographs of several ceramic reinforce-

ments that have been considered for discontinuous metal matrix
composite fabrication are presented in Figures 3 and 4. Most
recent interest has been focused on SiC whisker and particulate
reinforced powder-metallurgy aluminum alloys. SiC whisker manufac-
ture generally involves gas phase nucleation and growth, the
details of which are not well understood and apparently vary from
one manufacturer to another. Figure 3 shows that these manufactur-
ing variations result in distinct morphological differences among
various SiC whiskers.
SiC whiskers may be ~(BCC) or a mixture of ~ and a(HCP)
phases. Furthermore, the whiskers generally have a faulted
internal structure and an irregular surface, as shown, for
example, in Figure 5 for the ACMC SiC whisker(14). Finally,
initial whisker lengths may range between 5 and 40 ~m, Figure 6,
and normally contain SiC and/or Si02 particulates as contaminants,
Table 2.
 RACK
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FIG. 4 CONTINUED

A wide range of SiC particulate sizes and shapes are also

available. Again, both a and ~ SiC crystal structures have been
examined as possible reinforcements (13,15). Figure 7 shows a
typical particle size distribution for a SiC particulate. The
importance of selecting the appropriate SiC size to powder size
ratio has recently been demonstrated by ALCOA investigators
(16-18). These investigators showed that maximum toughness in
SiC p reinforced MB78, a 7000 series aluminum alloy, was associated
with a distinct SiC/AI powder size ratio, Figure 8.
Table 3 presents the chemical compositions of several
aluminum alloys that have been, or are being examined, as possible
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 335
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FIG. 4 CONTINUED

matrix alloys. Initially, standard wrought alloy compositions,

e.g. , 6061 and 2124 were utilized (19,20). These were prepared as
either elemental or pre-alloyed air/helium inert gas atomized
powders. Figure 9 illustrates the morphological features
characteristic of helium inert gas atomized powders. Typically,
the powders utilized in aluminum metal matrix composites have a
mean size of 15 ~m, nominally -325 mesh, Figure 10.
Recent investigations (12,23) have shown that that minor
alloying elements commonly included in wrought alloys as grain
refiners e.g., Mn and Cr, are unnecessary in discontinuously
reinforced metal matrix composites. Indeed, they may form large
 336 RACK
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FIG. 5 - Transmission Electron Micrograph of ACMC SiC Whisker

Illustrating Internal Faults and Irregular Surface.

30.----------,-----------,
F-9 WHISKERS

>- 20·-
o
z
w
a
w
e: 10

0.0 70.0 140.0

PARTICLE SIZE (MICRONS)

FIG. 6 - ACME SiC Whisker Size Distribution.

 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 337

TABLE 2
CHEMICAL COMPOSITION FOR ACMC SiC WHISKERS (12)

Grade
SC-9 SC-lO

Whisker content, % 80-90 70-80

Particle content, % 10-20 20-30
Element(ppm)
Ca 3700
Mn 2400
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A1 1300
Mg 800
Fe 500
Cr <50
Ni <50
K <50
Na <50
Cu <25
B <10
Li <10
Ti <10

30 -\-----+----1----+---\------+------11-----+----+
GRADE 3 SILICON CARBIDE PARTICULATE

25

z 20
Q

~
LL 15
....
~
~ 10

o 2 4 6 6 10 12 14 16
PARTICLE SIZE (MICRONS)

FIG. 7 - SiC Particulate Size Distribution.

 338 RACK

28 , ,
APD SIC: APD P/M 0-0.331
(SiCp reinforcement)
~ 26 r- o 15 v/o - T4
-
...
'in o 20v/o - T4

..
OJ
24 f-

0-0.24:\
-

c::
s:
go 22 f-
0-1:1
-
e
OJ
~
:> 20 r-
U

-...
a
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~
0-0.62:1
a
18 I- -
~

1:
0
.z:. 16 '- -
(I)
0.33:1-0
I 0-0.24:,1
I I
14
50 60 70 80 90 100
Tensile strength (ksi)

FIG. 8 - Influence of SiCp/Al Size Ratio on Fracture Toughness of

MB78(18). APD: Average Particle Diameter.

intermetallic compounds during consolidation and subsequent

processing, these compounds being detrimental to the composites'
tensile ductility. In addition, microstructural-mechanical
behavior examinations (12,24) of these alloys has shown that
leaner alloy compositions, that is alloys whose composition limits
lie on the lower end of the standard wrought alloy specification
limit, develop a better combination of strength, ductility and
toughness. Newer compositions have therefore eliminated Mn and/or
Cr, and have rebalanced (leaner) compositional limits.
Other matrix compositions that have been investigated include
7090, 7091, AI-Fe-Ce, AI-Cu-Mg-Li. These alloys take full benefit
of rapid solidification. However, they do require modification of
the consolidation and processing procedures described below.
A dry or wet blending operation typically follows selection
of the reinforcement and matrix powder. If whiskers or short
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 339

TABLE 3
CHEMICAL COMPOSITIONS OF ALUMINUM POWDERS

Element

------------------------------------------------------------------
Cu Mg Zn Si Mn Cr Fe Other
------------------------------------------------------------------
Al-eu
2219 6.74 0.4 0.05 0.12V
AI-Cu-Mg
2124 4.65 1. 60 0.01 0.04 0.9 0.3
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2124HP 4.65 1.5 0.02 0.1

2048 3.73 1.77 0.03
ACM1 2.95 1.37
ACM2 3.26 1.25 0.1 Zr
ACM3 3.67 1.84 0.14 0.2 0.2 0.6 Zr
A1-Mg-Si
6061 0.35 1.19 0.02 0.77 0.22 0.32
6013 0.75 1.15 0.94 0.22 0.1
AI-Zn-Mg-Cu
7075 1.5 2.5 5.5 0.30
7090 1.2 2.5 7.8 0.05 1.4 Co
7091 1.6 2.4 5.65 0.02 0.01 0.27 0.44 Co
SXA 60 1. 33 2.35 9.7 0.1 0.06
SXA 90 1. 31 2.49 7.8 0.02 0.03
AZMC1 0.79 3.56
AZMC2 0.68 0.98 4.18
MB78 2.0 2.0 7.0 0.14 Zr
AI-Li
ALI 1.0
AL2 2.0
AL3 3.0
AI-Mg
5082 4.5 0.7
AI-Cu-Mg-Li
ACML1 0.91 0.85 1. 66 Li
ACML2 0.63 0.68 1.0 Li
ACML3 1.5 1.0 2.8 Li
ACML4 3.0 1.0 1.6 Li
Other
AI-Fe-Ce 7.7 4.2 Ce
5.6 4.6 Ce,
0.3 II'
AI-Fe-Mo 6.1 1.5 Mo
AI-Fe-X 1.5 4.5 4.5 Ni
AI-Cr-X 0.8 3.8 1.3 Zr
 340 RACK
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FIG. 9 - Scanning Electron Micrograph of Helium Inert Gas Atomized

Aluminum.

2124 AlLm'
30 169-01-AI

25

20
z
0

..
;:
<J

...
0:
15

"'
'0-'"'
::>

>
10

0L--+-l--+---l1---+--+-+--+--11---+---l--+--+-+--+-+--+--l-...J
o 10 20 30 40 50 60 70 80 90 100 110 120 I~ 140 150 160 170 180
PARTICLE SIZE (MICRONS)

FIG. 10 - Powder Size Distribution for 2124 Helium Inert Gas

Atomized Aluminum.
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 341
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FIG. 11 - Silicon Carbide Whisker - Aluminum Blend.

fibers are to be included in the composite this blending step must

be preceeded by deagglomeration of the reinforcement. C. J.
Skowronek et. al. (25) have shown that this deagg10meration can be
accomplished thru ultrasonic agitation of alcohol fiber
suspensions. Figure 11 shows a typical SiC whisker/aluminum
powder blend produced in this manner. It also illustrates an
important characteristic of many whisker/powder blends, that is
the difference in size(diameter) of the whisker reinforcement and
the matrix powder. This difference can lead to whisker clumping,
early crack initiation and non-uniform precipitation (26-28).
While the difference between the aluminum powder and reinforcement
can be specified and controlled in particulate reinforced metal
matrix composites by suitable selection of powder and particulate
(16-18), the same approach cannot be utilized in short fiber/-
whisker metal matrix composites. In the latter, the whisker/fiber
diameters are fixed within a rather narrow size range (12). In
these composites improved mechanical working procedures offer the
only potential for minimizing the detrimental effects of dissimi-
 342 RACK

VACUUM
SEAL

VACUUM
CHAMBER
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VACUUM
(0) LOAD POWDER INTO VHP DIE AND ASSEMBLE SEAL

(b) HEAT MIXTURE/DIE IN VACUUM, OUTGAS

APPLIED
PRESSURE

APPLIED
VACUUM
PRESSURE
SEAL

TO VACUUM
PUMP

VACUUM
CHAMBER

HEATING .../
ELEMENT

VACUUM
SEAL

(e) COMPACT INTO BILLE T (d) STRIP BILLET FROM DIE

FIG. 12 - Schematic Representation of Vacuum Hot Pressing.

 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 343

TABLE 4

CHEMICAL REACTIONS OCCURRING DURING HEATING OF

ALUMINUM POWDERS (31)

> 100°C
AlZ03 • 3HZO ---------~ AlZ03 • HZO + HZO(g)
> 400°C
AlZ03 • HZO ---------~ AlZ03 + HZO(g)
> ZOOoC
ZA1 + 3HZO ---------~ AlZ03 + 3HZ (g)
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ZAI + 6HZO ---------~ AlZ03 • 3HZO + 3HZ (g)

lar powder and reinforcement diameters, that is hot/cold deforma-

tion enhances reinforcement-matrix mixing (Z9).
Final billet fabrication involves cold compaction, outgassing
and hot isostactic or vacuum hot pressing, Figure lZ. Cold compac-
tion densities should be controlled to maintain open, interconnect-
ing porosity. The latter is extremely important during the out-
gassing stage of the pressing operation. While the details of the
reinforcement-powder blend outgassing procedures are generally
considered proprietary by the composite manufacturer, they
normally involve removal of adsorbed or chemically bound water and
other volatile species through the combined action of heat, vacuum
and inert gas flushing. For example, outgassing of SiC reinforced
aluminum metal matrix composites involves removal of adsorbed
water from both SiC and aluminum, as well as chemically bound
water from the aluminum alloy. The principal reactions occurring
during this outgassing process are given in Table 4,
where HZ and HZO are the primary gaseous reaction products and
AIZ03 is the primary solid product.
The extent of these reactions during outgassing of SiC p and
SiC w reinforced 6061 Al blends is shown in Figure 13. These
results suggest that the outgassing reactions are a function of
the reinforcement surface chemistry. Other investigators have
 w
t:
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40 , 40 I • i i i i I
a b

~ 30
I ~ 30 I \ I
0' "0;
"0;
:x: :x:
t§
""c
ell
ell
a..
a. 20 I \\ \\
20 olI'> I \
lI'>
lI'>
C
en
::!: ' \ I
::!:
ell
ell >
"2:
C ~
Q; 10
Q;
a::
10 I "
"" 7
l '
\1
I I
0:

ok::?: -=r 100 200

<:1
300 400
I
HZO_

500
i-
C02
-)
600
o
I \.. U2
100
---a.
i i i
200 300
I
400
---
500
i
600

Temperature (OC) Temperature (OC)

FIG. 13 - Residual Gas Analysis of Outgassing Reactions in (a)

SiCp and (b) SiC w Reinforced 6061 Aluminum (31).

~
~
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 345

ligtll PVC
exterior
weother-

SiC
injection ~v
I
I
I
I
I
I
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I~
air___

FLOOR

FIG. 14 - Schematic Representation of Osprey Process (6).

also shown that the details of the reactions listed in Table 4 are
sensitive to the AI. alloy chemistry (30).
Once the desired isothermal temperature is reached, final
consolidation is accomplished by pressure application. Selection
of the consolidation temperature is typically based on the need to
minimize the pressures necessary for complete consolidation with-
 346 RACK
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FIG. 15 - Optical Micrograph of 11.5:1 Extruded SiC Reinforced

Aluminum.

out degrading the powder matrix. Preliminary data also suggest

that dynamic compaction may be an attractive alternative when deal-
ing with highly unstable rapidly solidified aluminum alloys (32).
Furthermore, while both solid state (16-18) and mushy zone (12)
consolidation temperatures have been employed, growing evidence
suggests that higher tensile ductilities can be achieved following
solid state pressing (33).
The second metal matrix billet manufacturing procedure
currently being developed by ALCAN involves direct incorporation
of the ceramic reinforcement in the matrix alloy as an integral
part of the Osprey process (5-7), Figure 14. While details of
this process are still under development, 6 in. diameter SiC p rein-
forced AC-Cu-Mg-Li alloys have been produced. These billets have
contained SiC having a mean diameter of 13 ~m and size range 5-20
~m.

After consolidation metal matrix composite billets are

homogenized, scalped and inspected. Typical inspection criteria
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 347

assure 98 percent theoretical density prior to subsequent

processing.

Primary Processing

Consolidated billets, typically 98+ percent theoretical

density, can be fabricated into a wide variety of shapes utilizing
standard metal working equipment. Primary working operations
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involving rolling, extrusion and forging have all been

demonstrated (13,24,34-36). Figure 15 demonstrates that an
extremely uniform distribution of SiC can be achieved in aluminum
matrix composites when proper processing procedures are utilized.
These procedures must however be adjusted, recognizing the forming
temperatures, deformation rates and flow conditions are uniquely
identified with each composite system (37). For example, control
of short fiber/whisker length-to-diameter ratio and orientation is
essential if the full benefits of this composite system are to be
realized. Short fiber length-to-diameter ratio and orientation in
extruded products may be controlled through proper choice of die
design, extrusion ratio, extrusion rate and deformation
temperature.
Figure 16 schematically compares two extrusion die geometries
currently employed for discontinuously reinforced aluminum metal
matrix composites (35). Figure 16(a) shows the flow fields
associated with a shear faced die, while Figure 16(b) shows those
of "stream-line" flow die. The latter die configuration has been
designed to simulate hydrostatic flow conditions, eliminating
re-entrant corners and "dead" zones where short fiber reinforce-
ments could undergo sharp velocity discontinuities. Table 5 shows
that when this die design approach is used for extrusion of 2124
containing 20 volume percent SiC whiskers, minimum whisker damage
occurred.
Heasurements of whisker orientation also suggest that only
moderate extrusion ratio's are required for essentially complete
alignment of SiC whiskers, Figure 17. While this alignment can be
 348 RACK
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- ~;

L.-- tID

17~D6······
I, lOJsUowmol11lg ---~- J.
e::::::t =~II'--

lCln0 _ _.--Iv

L.-- lQ)

FIG. 16 - Comparison of (a) Shear and (b) Streamline Flow

Extrusion Die Configurations.
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 349

TABLE 5
WHISKER ASPECT RATIO AS A FUNCTION OF PROCESSING (38)

Material L/D

Powder/whisker blend 19.8

36:1 Extrusion Ratio
Round-to-Round Through 18.0
Streamline Flow Die
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beneficial, for example, near rule-of-mixture elastic moduli can

be attained in properly processed extruded whisker reinforced
aluminum alloys, Figure 18, its presence does result in a highly
anisotropic fracture behavior (39).
Several methods of selecting the appropriate strain rates and
deformation temperatures for discontinuously reinforced metal
matrix composites have been suggested (37,40,41). Most are based
on experience or trial and error. One approach which appears to
warrant further consideration utilizes the material's true
stress-true strain rate constitutive behavior as a function of
strain rate and temperature (41). If the dynamic constitutive
behavior is represented by a relationship of the form,

a = A Em
where m is the strain rate sensitivity, then the deformation
efficiency, " that is the amount of energy transformed into shape
change, can be defined by
2m
, =m + 1

where m, is a function of both temperature and strain rate.

Figure 19 illustrates application of this technique to 2124
reinforced with 20 volume percent silicon carbide whiskers (42).
This data suggests that the maximum amount of useful work can be
obtained when deformation processing of this composite is carried
out at 485°C and 10- 4 sec-I.
 I' , , , , , , , , , , , , , , ....
b I
50
'"
0

, , , , , , , , , , I
40 I '
a
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4°l
•
30
•
(J)
a: 30
w
'"
(J)
:;:
(J)
a:
w
~

I- 20
'"
(J)
:;:
z
W
0
• • ~
I- 20
a:
w
c,
z
W
0
• •
a:
w
e,
10~
• 10
• r
• •
•
01 ~
• • • • I '
·80 -70 -60 -50 -40 -30 -20 -10
I
0 '0
,
20
• •
30
• •
40 50 60
.l J. ,
70
• '
•
1- •
•,
-80 -70 -60 -50 -40 -30 -20 -10
,
0 10 20
•
• ,
•
30 40 50 60 70 80

ANGLE ANGLE

FIG. 17 - SiC Whisker Distribution in Extruded 2124 Reinforced

with 20 Volume Percent SiC Whiskers (a) Surface
;<l
Orientation Plane and (b) Through Thickness Orientation >
()
Plane. Extrusion Ratio 11.5:1. ~
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 351

,...-----.-------..,.------,------r,------..., 30

SiC whiskers -I
(BCL Dolo)
20
t>
0- (/)
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c> ~
<Ii <Ii
" "
"
"t>
0 "
-e
0
~ ~

-
c.J

(/)
t>
W
-
o
(/)
t>

10 W

Curves based an'

E SiC = 431 GPo (62.5 Msi)

E 707 5 AI = 72 GPo (10.5 Msi)

I
o 0.\ 0.2 0.3 0.4

SiC Volume Fraction

FIG. 18 - Elastic Modulus of SiC Reinforced Aluminum Alloys.

The attainment of maximum useful work, as defined above, is a

necessary but not sufficient condition for establishing optimum
deformation parameters. For example, Gegel et. al. (42) have
shown that this maxima in 2124 reinforced with 20 volume percent
SiC whiskers, is associated with nearly complete dynamic recovery,
higher temperatures and rates leading to incipient melting, lower
temperatures and rates to dislocation accumulation. In contrast,
it is now well known however that maximum toughness in wrought
 352 RACK

~
,
~
~ -I r--...,--------,----,------,------,
II -2
~
~
~ -3

8'"75-4
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-.J

~
0
~

50
>-
u
z
w
U
u,
u, 25
w

0+---+---+--+---+---/
300 350 400 450 500 550
TEMPERATURE (C)

FIG. 19 - Influence of Temperature and Strain Rate on the

Deformation Efficiency (42).

aluminum alloys is generally associated with an unrecrystallized

grain structure. For example, further experimental examination of
the microstructural conditions associated with processing of SiC
reinforced 2124 has resulted in the deformation temperature being
lowered to 400°C (24).

Secondary Processing

Secondary processing procedures have included shear spinning

(43), superplastic forming (44-48) and joining (49,50). Figure
 POWDER-METALLURGY ALUMINUM MATRIX COMPOSITES 353

STRAIN RATE (~/min)

1,000
0.1
I . .,
1.0 10
-I .,
100
•
1,000
"1
10,000

SOD

§
z
0
ii
100 <- ...........---.--8-- ........... 8-~0
0
. -
Cl
2
9w
50
./0 • ~y
• LONGITUDINAL
'" o TRANSVERSE
Downloaded by [Moskow State Univ Bibliote] at 08:35 14 February 2014

.s
50~

'0
Q.
~

V> 10 ~
V>
UJ

'"f- 5
V>

• e
I .1 .I •1 .. .1
10"5 10"2
RATE (5')

FIG. 20 - Elongation and Flow Stress as A Function of Strain Rate

for 2124 Reinforced with 20 Volume Percent SiC Whiskers
(46) .

20 illustrates that elongations in excess of 300 percent can be

achieved in SiC reinforced 2124 thru proper selection of tempera-
ture and strain rate. Of particular interest are the rather high
strain rates associated with superp1asticity in reinforced
aluminum alloys when compared to other structural materials.
Finally, reinforced aluminum composites may be welded using a
variety of processes, providing that the composite is initially
given a vacuum heat treatment to minimize entrapped gases.

SUMMARY

This paper has reviewed the two primary powder-metallurgy

based fabrication methods currently under development for
 354 RACK

discontinuously reinforced aluminum metal matrix composites.

These procedures have a wide range of flexibility with each stage
of the manufacturing process ultimately having an effect on
mechanical, physical and environmental properties. While many of
these effects are not completely understood current knowledge does
exist for fabrication of billets up to 500 lbs. Future
advancements in manufacturing technology should allow this size to
increase as the demands of the market increase.
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ACKNOWLEDGEMENTS

The author wishes to express his appreciation for the continu-

ing support given to establishing a fundamental understanding of
the performance of discontinuous metal matrix composites by
NASA-Langley under grant NSG-1-724, W. Brewer contract monitor and
AFOSR under contract F49620-87-C-0017, Dr. A. Rosenstein contract
monitor.

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