2013 - Metal Matrix Composites Via PM Routes - Jill E. Erbrick

Metal Matrix Composites Via PM Routes
Jill E. Erbrick
Faculty Advisor: Wojciech Z. Misiolek
Institute for Metal Forming
Lehigh University
Bethlehem, PA, 18015
USA
Abstract:
The demand for metal matrix composites (MMCs) is increasing dramatically as more
applications require higher performance lighter weight materials. Powder Metallurgy (PM) is an
ideal method of fabrication for MMCs because of the ability to produce near net shapes and
little material waste associated with the process. Due to the increased strength associated with
the part after fabrication, machinability of the part can be difficult. This research examines the
best type of reinforcement fiber to be used with aluminum matrixes via PM routes, and the
effect that these fibers have on green strength of the part. The results show that alumina fibers
should be used in the form of either continuous or discontinues fibers to produce the highest
mechanical properties, whereas silicon carbide should be in the form or particulates and
whiskers.
Introduction:
Powder blending and consolidation, a solid state method of fabrication, consistently
produces superior mechanical properties distributed evenly throughout the material [2]. The
increase in strength observed after the sintering process decreases the machinability of the
material creating new challenges. Each MMC fabrication process varies in nature, resulting in
unequal costs and properties associated with the final components. Although the fabrication
method plays a role in the mechanical properties of the MMCs, the materials chosen for the
matrix and reinforcement fibers play an equally important role. Numerous metals including
aluminum, titanium, magnesium, and copper have been used as matrix materials in MMCs [3].
Aluminum is the most widely used matrix material in structural components as it provides
relatively high strength and toughness, while still remaining lightweight. In an effort to increase
the strength of the aluminum matrix while still maintaining the low density and moderate
ductility of the aluminum, reinforcement fibers of either alumina or silicon carbide are
distributed throughout the matrix.
When selecting materials for a MMC, it is critical that the materials selected for the
matrix and reinforcement fibers are not only evaluated on their individual properties, but also
on their reactivity with each other during the forming process. Often times the interactions
between matrix and fiber materials impose restrictions on the type of constituents that can be
combined [3]. In an attempt to reduce the reactivity of the constituents, a barrier coating is
often applied to the reinforcement. This barrier surrounds the reinforcement fibers preventing
any contact between the unstable constituents during the high temperature forming process
[3]. It is also critical to evaluate the temperature that MMCs will be subjected to in service in an
effort to prevent any potentially dangerous reaction between unstable constituents.
Results and Discussion:
Reinforcement fibers are produced in four forms: continuous, discontinuous, whiskers,
and particulates as seen below in Figure 1 A-D [4]. Aluminum matrix composites (AMCs) can be
enhanced with any of the above fiber types; however, not all reinforcement materials can be
fabricated into a specific fiber form. For example, in an aluminum matrix, alumina fillers
produce the highest mechanical properties when they are in the form of a continuous or
discontinuous fiber, whereas silicon carbide produces superior properties in the form of
particulates and whiskers [3].
B
A
C D
Figure 1: Types of reinforcement fibers used in MMCs A) Continues Fibers B) Discontinuous

Fibers C) Whiskers D) Particulates
In comparison with the matrix material, particulate reinforced MMCs often show a large
increase in strength, but also a reduction in ductility and fracture toughness resulting from the
addition of brittle particulates within the matrix [3]. Isotropic behavior is also characteristic of
particulate reinforced MMCs, since particles are distributed evenly throughout and cannot align
in any particular direction to provide increased strength. In opposition of particulate reinforced
MMCs, the mechanical properties associated with whisker reinforced MMCs is strongly
dependant on their orientation. Randomly oriented whiskers will essentially act as large
particulates dispersed within the matrix, resulting in isotropic behavior. Unlike particulates
though, extrusion can be used to align the whiskers resulting in anisotropic behavior [4]. It is
important to not only consider the filler fiber and its orientation within the matrix, but also the
effect that the matrix material has on the overall composite behavior. Stress –strain curves
generated from MMCs often display non-linear behavior resulting from the yielding of the
matrix before the reinforcement.
Although there are many other methods of MMC fabrication, it is clear that powder
metallurgy (PM) produces a product with exemplary strength and toughness. Although this
increase in strength is highly coveted and necessary for the materials intended application, it
presents a new challenge. After the sintering process, the MMCs have such high strength that
they are extremely difficult to machine to final specifications [5]. Although PM produces net or
near-net shapes, over 60% of the parts will still need to undergo some form of machining that
cannot be achieved by die pressing [6]. This additional machining leads to additional production
costs since it is more difficult to machine porous PM parts than pore-free material. Machining
costs can easily add up to 20% of the overall production costs of a part [6]. In order to be
competitive in industry, it is critical to reduce these costs either by optimization of the
machining process or modification to the production process.
Green machining of the parts has the potential to reduce costs associated with
machining due to their decreased strength. Warm die compaction and advanced lubrication
systems with binding agents have resulted in an increase in green strength by 10 N/mm2 over
traditional die pressing technology [6]. In response to this increase in strength of the green
compact, it is now possible to perform machining operations before the sintering process.
Although the material is strong enough to withstand machining, the quality will not be as high
as if completed post sintering. The green compacts flake and disintegrate around the edges
where the tool enters and exits the compact. However, minor surface defects are produced [5].
As a result of this, it is recommended that green machining only occurs in applications with
medium quality demands. Despite the fact that the green strength obtained by new
technologies is higher than previous methods, the materials are still extremely brittle. In order
to successfully machine the compacts the cutting forces must be reduced as much as possible,
which can be achieved by using sharp tool geometries and lowering the feed rate [6].
Conclusion:
The formation of MMCs via PM routes was investigated in this research. The following
conclusions can be made:
1. PM is suitable for the production of MMCs that require high strength while
maintaining low density.
2. The type of reinforcement fiber will affect the mechanical properties of the part.
Alumina should be in the form of continuous or discontinuous fibers, silicon carbide in form of
particulates or whiskers.
3. Increase in green strength associated with MMCs allows for green machining, but
only produces mid-range quality products.
Acknowledgements:
The author would like to thank Dr. Wojciech Z. Misiolek, Loewy Professor in the Institute
for Metal Forming at Lehigh University for his advice throughout this course of study. Also many
thanks to the Center for Powder Metallurgy Technology and Arlan J. Clayton for their financial
support, which made this project possible.

Literature:
[1] Kunze, Joseph M., and Clifford C. Bampton. "Challenges to Developing and Producing MMCs for
Space Applications." SpringerLink. Springer Science Business Media, 04 Nov. 2001. Web. 18 Apr. 2012.
<http://www.springerlink.com/content/75uw4w76n0053w60/>.
[2] "Metal Matrix Composites." Metal Matrix Composites. Composite Metal Technologies PLC. Web.
07 Apr. 2012. <http://www.cmt-ltd.com/html/mat_1.htm>.
[3] "Metal Matrix." Metal Matrix. Composites-by-Design. Web. 18 May 2012.

<http://clev11.com/~composi1/?page_id=25>.
[4] Callister, William D. Materials Science and Engineering: An Introduction. Hoboken, NJ: John
Wiley & Sons, 2006. Print.
[5] Cimino, T. M., and S. H. Luk. "Machinability Evaluation of Selected High Green Strength PM
Materials." PM2 TEC. Seattle. 14 May 1995. Speech.
[6] Benner, A., and P. Beiss. "Wear Aspects During Green Machining on Warm Compacted PM
Steels." 35.10 (2004): 663-69. Web. 07 Apr. 2012.

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Metal Matrix Composites Via PM Routes

Powder blending and consolidation, a solid state method of fabrication, consistently

distributed throughout the matrix.

effort to prevent any potentially dangerous reaction between unstable constituents.

Results and Discussion:

Reinforcement fibers are produced in four forms: continuous, discontinuous, whiskers,

particulates and whiskers [3].

Figure 1: Types of reinforcement fibers used in MMCs A) Continues Fibers B) Discontinuous

in any particular direction to provide increased strength. In opposition of particulate reinforced

matrix before the reinforcement.

competitive in industry, it is critical to reduce these costs either by optimization of the

machining process or modification to the production process.

conclusions can be made:

maintaining low density.

only produces mid-range quality products.

support, which made this project possible.

[3] "Metal Matrix." Metal Matrix. Composites-by-Design. Web. 18 May 2012.

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