GROUP # 08

TOPIC:

METAL MATRIX COMPOSITES.

&
CERAMIC MATRIX
COMPOSITES
INTRODUCTON

Engineer traditional considered the metal the most important class of engineering
materials, but interesting to know that composites are more appreciable and
abundant use in nature.
COMPOSITES???
“Composites is a material composed two or more physically distinct
phases whose combination produce aggregate properties that are different from
those of it’s constituents”

Question arises.

How commercial interest drives for composites??

 Commercial interest in composites materials derive from their properties.

PROPERTIES OF COMPOSITES:

 Very strong, stiff and lighter in weight.

 Strength to weight and stiffness to weight ration is several ties higher than steel.
 Have a corrosion resistance so use in automotive and other apllications.
 Fatigue properties are generally better than common engineering material.
 It is possible to achieve combination of properties not attainable with metals,
ceramics and polymers alone
 Very smooth and better appearance is controlled in certain cermamics.

 EXAMPLES:
 Cemented carbide, rubber mixed with carbon black, Titanium carbide (TiC),
Chromium carbide (Cr3C2),Tantalum carbide (TaC) etc.
 CLASSIFICATION OF COMPOSITE
MATERIALS
Composites material consist of two distinct types by nature.
Traditional composites:
wood.
Concrete.
Bamboo.
Adobe bricks. ( mud and straw).
Synthetic composites:
Different types of composites are invent to achieve our desire material
properties, linked with modern material system associated with industries, like cermets,
cemented carbides.

Components of composite materials

Reinforcement: fibers Matrix materials Interface
Glass Polymers Bonding
Carbon Metals surface
Organic Ceramics
Boron
Ceramic
Metallic
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 HOW TO FORM COMPOSITES?
There are two phases.
 Matrix (primary phase)
 Reinforcement phase (secondary phases).
• The reinforcement is stronger and stiffer, forming a sort of backbone, while
• The matrix keeps the reinforcement in a set place. The binder also protects the
reinforcement, which may be brittle or breakable.
 EXAMPLE:
 Humans have been creating composite materials to build stronger and lighter
objects for thousands of years.
 The most primitive composite materials comprised straw and mud in the form of
bricks for building construction. Mud is an excellent binding material, but it cannot
stand up to compression and force well. Straw, on the other hand, is well able to
withstand compression without crumbling or breaking, and so it serves to reinforce
the binding action of the mud.
Secondary phase
,reinforcement Primary phase, matrix
Metal Ceramic Polymer

Metal Powder metallurgy parts – Cermets (ceramic-metal Brake pads

combining immiscible composite)
metals

Ceramic Cermets, TiC, TiCN SiC reinforced Al2O3 Fiberglass

Cemented carbides – used Tool materials
in tools
Fiber-reinforced metals

Polymer     Kevlar fibers in an epoxy

matrix

Elemental (Carbon, Fiber reinforced metals   Rubber with carbon (tires)

Boron, etc.) Auto parts Boron, Carbon reinforced
aerospace plastics

MMC’s CMC’s PMC’s

Metal Matrix Composites Ceramic Matrix Comp’s. Polymer Matrix Comp’s
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Classification of composite material

 Metal Matrix Composites (MMCs)

 Include mixtures of ceramics and metals, such as cemented carbides
and other cermets, as well as aluminum or magnesium reinforced by
strong, high stiffness fibers

 Ceramic Matrix Composites (CMCs)

 Least common composite matrix. Aluminum oxid and silicon carbide
are materials that can be imbedded with fibers for improved properties,
especially in high temperature applications

 Polymer Matrix Composites (PMCs)

 Thermosetting resins are the most widely used polymers in PMCs.
Epoxy and polyester are commonly mixed with fiber reinforcement.
METAL MATRIX COMPOSITES
 A metal matrix composite (MMC) is composite
material with at least two constituent parts, one
being a metal. 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.
METAL MATRIX COMPOSITES
Cemented carbides are composed of one or more
Carbide compounds bonded in a metallic matrix

Common cemented carbides are based on:

 Tungsten carbide (WC)
 Titanium carbide (TiC)
 Chromium carbide (Cr3C2)
 Tantalum carbide (TaC)

Carbide ceramics constitute the principal ingredient in cemented carbides,

typically ranging in content from 80% to 95% of total weight.

Principle metallic binders are:

 Cobalt – used for WC
 Nickel - used TiC and Cr3C2

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Processing of MMC’s
 Solid state method.
 Liquid state method.
 Physical vapour deposition.
 Insitue fabrication technique.

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Manufacturing and forming methods
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.

Liquid state methods:

 Electroplating / 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.
 Squeeze casting: Molten metal is injected into a form with fibers preplaced 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.
Manufacturing and forming methods
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.
 USES OF MMC:
Due to hardness and high wear resistance we can use metal
matrix (cemented carbide) composites for tooling in different
manufacturing processes
• Carbide cutting tools.
• Cemented carbide is used for wire drawing dies.
• Rock drilling bits and other mining tools.
• Dies for powder mettalurgy.

 Due to high temperature applications titanium carbide have a following uses.

• It is used in gas turbine nozzle vanes.
• Used for valve seats, thermocouple protection tubes.
• Hot working spinning tools.
Most important uses of metal matrix composites are in aircrafts and
because of high strenght-to-weight ratio, and due to high temperature
strenght properties and good electrical and thermal conductivity they are
mostly used in turbine machinery.
USES OF MMC:

Cemented carbide tools

Rock drilling bits and tips

Ceramic Matrix Composite
(CMC)
Ceramic Matrix composites
Ceramic matrix composites (CMC) are used in applications where
resistance to high temperature and corrosive environment is desired.
CMCs are strong and stiff but they lack toughness (ductility)

Matrix materials are usually silicon carbide, silicon nitride and aluminum
oxide, and mullite (compound of aluminum, silicon and oxygen). They
retain their strength up to 3000 oF.

Fiber materials used commonly are carbon and aluminum oxide.

Applications are in jet and automobile engines, deep-see mining,

cutting tools, dies and pressure vessels.

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PROPERTIES OF CMC
ADVANTAGES:
 High stiffness, hardness, hot hadness.

 Compressive strenght.

 Low density.

DISADVANTAGES:
 Low toughness.

 Bulk tensile strength.

 Thermal cracking.

TECHICAL DIFFICULTIES:
 Difficulties including thermal and chemical compatibility of the
constituents in the CMC, during proccessing and also limting
ceramic material used.
MATERIALS FOR CMC.
PRIMARY PHASE MATERIALS(MATRIX) SECONDRY PHASE
MATERIALS(REINFORCING AGENT)
 Alumina.
 Boron nitride.  Short fibers such as whiskers.
 Boron carbide.  Long fibers used in particular
processing methods.
 Titanium carbide.
 Silicon carbide.
 Silicon nitride.
Purpose of using CMC
 Increase the toughness
PROCCESSING OF CMS
 Formation of raw material.
 Crushing.
 Grinding.
 Shaping proccess.
 slip casting.
 Platic forming.
 Semi dry pressing.
 Dry pressing.
 Drying.
 Firing.
 Finishing.
SHAPING PROCCESS.
PLASTIC FORMING
Slip casting
SEMI-DRY PRESSING
Dry pressing
DRYING
Application of Composites

Lance
Lance Armstrong’s
Armstrong’s 2-lb.
2-lb.
Trek
Trek bike,
bike, 2004
2004 Tour
Tour de
de
France
France

Pedestrian
Pedestrian bridge
bridge inin
Denmark,
Denmark, 130
130 feet
feet long
long
(1997)
(1997)

Swedish Navy, Stealth

(2005)

35
Due to weight-to-strength and weight-to-
stiffness ratio we can use it in airplane
Conclusion:
There is so many categories of engineering materials are using
in the whole world and further advancements and modifications are
happening in that all. After examine our environments and world
resources further we have to compete for the materials that are able
to be
 Recycled again and again.
 Having good engineering properties.
 Easily available.
and so many like this.
 THANK YOU FOR YOUR ATTENTION

Lecture-05: Sheet Metal Forming Processes 34/39