Al- Particulate MMC’s

• Al- Particluate MMC’s – very popular

• relative ease of fabrication
• Variety of techniques
• Wide choice of matrices (wrought, cast, heat
treatable…)
• Wide choice of reinforcements ( hard, soft..)
• Relatively low cost of reinforcements and
fabrication

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 Al MMC’s- Hybrid composites
• Hybrid composites- multiple reinforcements’
• It is possible to add more than one
reinforcement
• Each reinforcement has its own function
• Examples include SiC- Graphite, Alumina-
MoS2

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Classification of Production techniques
for MMC’s
• Major classes of Production techniques for MMC’s
• Solid State Techniques – involves no melting
Important techniques include: Powder Metallurgy
(P/M) and Diffusion Bonding (DB)
• Liquid State Processing Techniques- involves melting and
subsequent processing of the melt.
Important techniques include: stir casting and Spray Forming (
Osprey process)
• Semi-Solid Processing Techniques: involves processing of the melt
in the semi-solid condition
Important techniques include: Thixocasting and compo casting

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Al MMC’s- Important Production
Methods

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 Production of MMC’s- Solid State
• Techniques
Powder Metallurgy (P/M) – most common solid state
processing technique
• Involves mixing, pressing and consolidation
• mixing – to obtain a uniform distribution of various
ingredients ( matrix alloy, reinforcing phases , lubricants..)
• Pressing – to obtain the desired shape of the component
- may be done using die pressing, cold isostatic pressing
• Consolidation- to promote metallurgical bonding and to
obtain the finished product
-done by conventional sintering
• alternately Hot Consolidation by Hot Pressing or Hot Isostatic
Pressing can be done.

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Powder Metallurgy Processing of P/M parts

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 Powder Metallurgy Processing of
Conventional P/M processing Steps: MMC’s
• Mixing – mixing of ingredients- uniform distribution is essential
• major isssues: density differences between matrix and reinforcements – segregation –
non-uniform properties
• lubricants- amount- distribution- porosity
• Die-Pressing- pressing the mixed powders to obtain a green compact
•major issues: i) die design- choice of die material ,elastic spring back- component, size (
small, mediu…) , shape( simple, complex..)
ii) density differences within the compact- single-ended and double ended compaction,
floating die compaction

• Sintering: Furnace types ( normal, vacuum) – need for atmospheres ( reduction of

surface oxides, prevention of oxidation…)

• Finishing operations- machining, heat treatment, plating..

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Powder Metallurgy Processing of
MMC’s
Hot Extrusion of Powder Mix:
Mixing of ingredients, followed by hot extrusion

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 Powder Metallurgy Processing of
MMC’s
• Hot Pressing- Simultaneous application of
uniaxial pressure and temperature to the
powder mixture kept in a graphite die
• Better densification than conventional
sintering ( 90- 95% TD)
• Higher cost ( costly dies- HD graphite)

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Powder Metallurgy Processing of MMC’s

Hot Pressing of
MMC’s

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