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SELECTION OF MATRIX

AND REINFORCEMENT
MMC, PMC, CMC

BY
PADMANABHAN.K

Reinforcements

Fiber

Reinforcement usually adds rigidity and greatly impedes crack propagation.


Thin fibers can have very high strength, and provided they are
mechanically well attached to the matrix they can greatly improve the
composite's overall properties.
Fiber-reinforced composite materials can be divided into two main
categories normally referred to asshort fiber-reinforced materialsand
continuous fiber-reinforced materials. Continuous reinforced materials will
often constitute a layered or laminated structure. The woven and
continuous fibre styles are typically available in a variety of forms, being
pre-impregnated with the given matrix (resin), dry, uni-directional tapes of
various widths, plain weave, harness satins, braided, and stitched.
The short and long fibers are typically employed in compression moulding
and sheet moulding operations. These come in the form of flakes, chips,
and random mate (which can also be made from a continuous fibre laid in
random fashion until the desired thickness of the ply / laminate is
achieved).
Common fibers used for reinforcement include glass fibers, carbon fibers,
cellulose (wood/paper fiber and straw) and high strength polymers for
examplearamid.Silicon carbidefibers are used for some high temperature

Other Reinforcement

Concrete usesaggregate, and reinforced


concrete additionally uses steel bars (
rebar) to tension the concrete. Steel
mesh or wires are also used in some
glass and plastic products.

Metal matrix composite

Ametal matrix composite(MMC) is


composite materialwith at least two
constituent parts, one being ametal
necessarily, the other material may be a
different metal or another material, such
as aceramicororganic compound. When
at least three materials are present, it is
called ahybrid composite. An MMC is
complementary to acermet.

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 fibersare commonly used
inaluminiummatrix to synthesize composites
showing low density and high strength.
However, carbon reacts with aluminium to
generate a brittle and water-soluble
compoundAl4C3on the surface of the fibre. To
prevent this reaction, the carbon fibres are
coated withnickelortitanium boride.

Matrix

The matrix is themonolithicmaterial 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 asaluminum,
magnesium, ortitanium, and provides a
compliant support for the reinforcement. In
high-temperature applications,cobaltand
cobaltnickel 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,frictioncoefficient, orthermal conductivity. The
reinforcement can be either continuous, or discontinuous. Discontinuous
MMCs can beisotropic, 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).
Continuous reinforcement uses monofilament wires or fibers such as
carbon fiberorsilicon carbide. Because the fibers are embedded into the
matrix in a certain direction, the result is ananisotropicstructure in
which the alignment of the material affects its strength. One of the first
MMCs usedboronfilament as reinforcement. Discontinuous
reinforcement uses"whiskers", short fibers, or particles. The most
common reinforcing materials in this category arealuminaand
silicon carbide.[1]

Manufacturing and forming methods

Solid state methods


Liquid state methods
Semi-solid state methods
Vapor deposition
In-situ fabrication technique

Applications

High performancetungsten carbidecutting toolsare made from a toughcobalt


matrix cementing the hard tungsten carbide particles; lower performance tools
can use other metals such asbronzeas the matrix.
Some tank armors may be made from metal matrix composites, probably steel
reinforced withboron nitride, which is a good reinforcement for steel because it is
very stiff and it does not dissolve in molten steel.
Someautomotivedisc brakesuse MMCs. EarlyLotus Elisemodels used aluminum
MMC rotors, but they have less than optimal heat properties and Lotus has since
switched back to cast-iron. Modern high-performancesport cars, such as those
built byPorsche, use rotors made of carbon fiber within a silicon carbide matrix
because of its highspecific heatand thermal conductivity.3Msells a preformed
aluminum matrix insert for strengthening cast aluminum disc brake calipers,[1]
allowing them to weigh as much as 50% less while increasing stiffness. 3M has
also used alumina preforms for AMCpushrods.[2]
Fordoffers a Metal Matrix Composite (MMC)driveshaftupgrade. The MMC
driveshaft is made of an aluminum matrix reinforced withboron 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.

PMC

Thermosets and thermoplastics

Advanced composite systems are divided


into two basic types, thermosets and
thermoplastics. Thermosets are by far the
predominant type in use today.
Thermosets are subdivided into several
resin systems including epoxies,
phenolics, polyurethanes, and
polyimides. Of these, epoxy systems
currently dominate the advanced
composite industry.

Thermosets

Thermosetresins require addition of a


curing agentor hardener and
impregnation onto a reinforcing material,
followed by acuring stepto produce a
cured or finished part. Once cured, the
part cannot be changed or reformed,
except for finishing. Some of the more
common thermosets includeepoxy,
polyurethanes, phenolic and amino
resins,bismaleimides(BMI, polyimides),
polyamides

Thermoplastics

Thermoplasticscurrently represent a
relatively small part of the ACM industry.
They are typically supplied as
nonreactive solids (nochemical reaction
occurs during processing) and require
onlyheat and pressureto form the
finished part. Unlike the thermosets, the
thermoplastics can usually be reheated
and reformed into another shape, if
desired.

Ceramic matrix composite

Ceramic matrix composites


(CMCs)are a subgroup of
composite materialsas well as a
subgroup oftechnical ceramics. They
consist of ceramicfibresembedded in a
ceramic matrix, thus forming aceramic
fibre reinforced ceramic
(CFRC)material. The matrix and fibres
can consist of any ceramic material,
wherebycarbonandcarbon fibrescan
also be considered a ceramic material.

In ceramic matrix composites, a given ceramic matrix is


reinforced with either discontinuous reinforcement, such as
particles, whiskers or chopped fibers or with continuous
fibers. The basic reinforcements which are included in the
ceramic matrices are carbon, glasses, glass-ceramics,
oxides and non-oxides. The main function of the matrix is to
keep the reinforcing phase in the desired orientation or
location and act as a load transfer media as well as protect
reinforcement from the environment. Whereas, the primary
aim of the reinforcement is to provide toughness to an
otherwise brittle matrix. Filler materials in particle form are
also sometimes added to the matrix materials during the
processing of CMCs to enhance the properties such as
electrical conductivity, thermal conductivity, thermal
expansion and hardness.

The schematic of morphology of the


different particulate reinforcements is
shown in Figure 1. Figure 1 Particulate
morphology
(a) Spherical (b) Irregular (c) Faceted

Ceramic matrix composites (CMCs) can


be processed either by conventional
powder processing technique or by other
more specific and customized techniques.

Advantages of ceramic matrix composites


a) Excellent wear and corrosion
resistance in a wide range of
environments and temperatures b)
Higher strength to weight ratio c) Higher
strength retention at elevated
temperature d) Higher chemical stability
e) Non-catastrophic failure f) High
hardness g) Lightweight

Disadvantages of ceramic matrix composites a)


Processing routes for CMCs involve high
temperatures can only be employed with high
temperature reinforcements (a) (b) (c) b) CMCs are
designed to improve toughness of monolithic
ceramics, the main disadvantage of which is
brittleness c) High processing temperature results
in complexity in manufacturing and hence
expensive processing d) Difference in the
coefficients of thermal expansion between the
matrix and the reinforcement lead to thermal
stresses on cooling from the processing
temperatures

Applications

Ceramic matrix composites overcome the


major demerits (such as brittle failure, low
fracture toughness and limited thermal shock
resistance) of monolithic ceramics. Therefore,
the use of these materials has captured the
fields where high temperature and excellent
wear and corrosion resistance are the principal
matters of concern. One of the most important
applications of ceramic matrix composites is in
production of cutting tools which are made up
of SiC whisker reinforced aluminium oxide for
machining of hard to machine materials.

NATURAL FIBERS

Natural fibers

abaca, coconut, flax, hemp, jute, kenaf and


sisal are the most common are derived
from the bast or outer stem of certain plants.
They have the lowest density of any
structural fiber but possess sufficient stiffness
and strength for some applications.
The automotive industry, in particular, is
using these fibers in traditionally unreinforced
plastic parts and even employs them as an
alternative to glass fibers. European
fabricators hold the lead in use of these
materials, in part because regulations require
automobile components to be recyclable.

Types of Natural Fiber

Banana Fiber

SugarcaneBagasse
Fiber

Kenaf Fiber

Jute Fiber

Hemp Fiber

1. Car partsApplications

Exterior body
parts

Car
Hood

Front bumpers
and fenders

Door
panels
Various interior
parts

Natural fiber composites vs. synthetic fiber composites


Study

Materials

Application

Performance

Schmidt & Meyer Hemp-EPDM-PP Auto Insulation


Hemp fibers are
(1998)
vs. GF-EPDMcomponent (Ford able to replace
PP
car)
glass fibers
Diener & Siehler
(1999)

GF-PP vs. FlaxPP

Auto car panel


Successfully
(Mercedes A car) passed all test

Wotzel et al.
(1999)

Hemp Epoxy
vs. ABS

Auto side panel

Do not discuss
the performance

CorbiereNicollier et al.
(2001)

China reed-PP
vs. Glass-PP

Transport pallet

Satisfying
service
requirement

Source : Joshi et al. (2003)

Weight Reduction
Component

Study

NFRP
component

Base
component

Auto side panel

Wotzel et al.

820 g (hempepoxy)

1125 g (ABS)

Auto insulation

Schmidt &
Meyer (1998)

2.6 kg (hempPP)

3.5 kg (GF-PP)

Transport-Pallet

CorbiereNicollier et al.
(2001)

11.77 kg (China
reed PP)

15 kg (GF PP)

Source : Joshi et al. (2003)

2. Recreation and Leisure

Railing
Patio furniture

Decking product

3. Insulated Roofing

Roof
sandwich
with foam
core

Roof
sandwich
structure
with
bamboo
core

Applications
4. Door panel

Thank
You

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