Bag composites
Metal matrix Moulding Technique
The family of materials classified as metal-matrix composites
(MMCs) comprises a very broad range of advanced
composites of great importance to both industrial
(automobile) and Aerospace & Defence applications.
However, the development and use of MMCs are still in their
infancy when compared to monolithic materials or even
Polymer resin-matrix composite systems.
Therefore, only a handful of applications have been designed
and produced, but these are illustrative of the potential of
MMCs.
Metal matrix composites
Bag Moulding Technique
Metal matrix composites have a metal matrix usually of
lighter metal such as (Al, Mg or Ti) or a Super alloy (Ni based
or Co based superalloy).
The reinforcement materials include Boron, Silicon carbide,
carbon, graphite, alumina, Boron carbide, Boron nitride or
metallic systems like lungsten, Beryllium or steel.
The form of reinforcement material can be either fiber or
whisker or particulate.
Metals are reinforced either to increase certain properties like
elastic modulus and tensile strength or decrease certain
properties like coefficient of thermal expansion and thermal
conductivities.
Metal matrix composites
Bag Moulding Technique
Following are the important MMC's:
• Boron fiber in Al alloy matrix
• Graphite or carbon fiber in Al alloy matrix
• SiC fiber in Al alloy matrix
• Alumina fiber in Mg alloy matrix
• Borsic fiber in Ti alloy matrix
• Tugsten fiber in Ni based superalloy
• Glass fiber in Lead alloy
Metal matrix composites advantages
Bag Moulding Technique
Very high specific strength and specific modulus
Low thermal coefficient of thermal expansion
Retention of properties at higher temperatures
Higher operating temperature
Mechanics of Composites Materials
Insensitivity to moisture
Non-flamability
Better capability to withstand compression and shear loading
Bag Moulding Technique
Metal matrix composites Limitations
Higher densities as compared to PMC's
MMC's demand higher processing temperatures
Processing methods are expensive
MMC's are expensive as compared to PMC's
Bag Moulding
Selection of Base Metals
Technique
Current technology is mainly focused in reinforcing light
metal matrices such as (Al, Mg or Ti) or a Super alloy (Ni
based or Co based superalloy).
Metals are reinforced either to increase certain properties like
elastic modulus and tensile strength or decrease certain
properties like coefficient of thermal expansion and thermal
conductivities.
The purpose of reinforcing light metals is to increase the
specific strength and specific modulus.
Selection of Base Metals
Bag Moulding Technique
By Rule of Mixtures, we have:
Ec = Vm . Em + Vf .Ef
Where,
Em : Young's Modulus of matrix
Ef : Young's Modulus of fiber
Vf : Volume fraction of fiber
Vm = Volume fraction of matrix
For e.g., with the addition of 50% Boron fibers in Al alloy 6061, the
strength increased from 310 MPa to 1417 MPa and tensile modulus
increased from 70 GPa to 231 GPa.
Bag Moulding Technique
Fabrication of Metal matrix composites
Solid state fabrication
Co-deposition of matrix and reinforcement particulates
Liquid state fabrication
In-Situ Fabrication
Bag Moulding
Co-Deposition Technique
This technique involves simultaneous deposition of both
matrix and reinforcement in the form of atomised powders on
a substrate.
Then extracting the component from the substrate.
Two techniques are popular:
Plasma spray co-deposition
Osprey process
Bag Moulding Technique
Plasma spray co-deposition
Plasma spray co-deposition is a versatile technique for
depositing metal vapours on a substrate where in
discontinuous fibers are laid up according to the desired
orientation.
After spraying operation, the composite material is
compacted either by cold iso-static or hot iso-static pressing.
Bag Moulding Technique
Plasma spray co-deposition
Plasma spray co-deposition Process
Bag Moulding Technique
Substrate is properly laid up with fibers with desirable orientation
and volume fraction.
Plasma zone is produced by arc discharge between W electrode
(cathode) and water cooled Cu electrode (anode).
An inert gas atmosphere is maintained around the plasma zone.
Ar or He along with 2% of Nitrogen is used as the shielding gas
mixture.
Metal powders are inserted into the plasma zone which entrains
the high velocity plasma jet.
The powder melts and the molten metal droplets solidify at the
rate of 10^5 K/sec and gets deposited on the substrate.
Bag Moulding Technique
Plasma spray co-deposition Process
Discontinuous laminate composite structures can be obtained by a
powder blend of two or more different constituents.
Instead of static substrate, one can have a rotating mandrel and
two plasma guns with two different metal feed units.
Alternate deposits of matrix and reinforcement materials can be
obtained by the two plasma guns which could be traversed across
the mandrel.
Bag Moulding Technique
Different combinations of composites can be made by this
process.
Brittle matrix - Brittle reinforcement
Brittle matrix - Ductile reinforcement
Ductile matrix - Brittle reinforcement
The deposits can be further compacted in hot press to densify the
part.
Bag Moulding
Osprey Process Technique
It involves atomizing a melt and introducing reinforcement
particles into the spray of fine metal droplets.
The metal and reinforcement are then deposited on a substrate.
The atomized particles exists as discrete particles for a very short
times (few milliseconds) and rapid solidification leads to fine
micro-structure and reduces the possibility of extensive chemical
reaction.
Control of atomization of particle feeds enables an MMC with
acceptable density. This technique is mainly used for SiC
reinforcement of Al alloys.
Bag
Liquid state Moulding
fabrication Technique
technique
In recent years, work is being concentrated to produce MMC's
using conventional Casting techniques.
The major barriers to this type of process are the non-wetting of
the reinforcement and also adverse chemical reaction between
the matrix and reinforcement.
Various approaches are being tried to overcome these problems.
For example, specially graded pyrolytic graphite coatings are to
SiC so as to increase the wettability.
Alternately, matrix composition is modified to aid processing.
Bag Moulding Technique
Liquid state fabrication technique
The simplest liquid state technique is melt stirring (stir casting).
Here the Al molten metal is stirred continuously with SiC particles
and cast in a conventional manner.
Even with stirring, because of the density differences, it is difficult
to ensure uniform mixing.
This can be improved by allowing the molten metal to semi-
viscous state and stirring is done. This technique is called compo-
casting or rheo-casting.
Bag Moulding Technique
Squeeze Casting
Squeeze casting is also known as "liquid forging”.
In the initial stages of development, this technique was used to
make pore-free, fine grained Al alloy component having superior
properties.
The components produced by this method was preferred as
against conventional casting.
This method was particularly useful for Al-Si casting.
Bag Moulding Technique
Squeeze Casting
Squeeze Casting
Bag Moulding Technique
A porous preform (generally discontinuous alumina fibers) is first
inserted into the Die.
Molten metal (generally Al) is poured into the Die which is pre-
heated to around 200°C.
Die is located in the bed of an hydraulic press.
The Ram of the Press is now pressed to penetrate the fibers into
the molten metal.
Applied pressure is of the order of 70-100 MPa.
Fiber orientation and volume fraction are important parameters in
controlling the resistance against wear and protection of ram
against seizure.
Squeeze Casting
Bag Moulding Technique
Solidification of the matrix is completed under pressure. After
solidification, the part is ejected by a piston mounted in the
hydraulic bed.
For high speed Diesel engine, pistons made of such composite has
low weight (11% lower) and with very high wear resistance.
The liquid metal infiltrates into the fiber bundles by capillary
action. It is very important that the molten metal wets the fiber
interface.
Squeeze casting techniques are now being employed in the
manufacture of combustion chambers where outer layers of the
component must resist temperature excursions and do not get
damaged due to thermal fatigue problem.
Bag Moulding
Liquid Metal infiltration Technique
In liquid metal infiltration process, the pressure is applied through
a gas.
The pre-form is inserted into the Die.
The chamber containing the molten metal is evacuated and then a
gas is forced into the chamber to infiltrate the pre-form.
The pressure causes the molten metal to infiltrate the pre-form.
The pressure is maintained for a short duration of time for
solidification.
Bag Moulding Technique
Liquid Metal infiltration
Composites definition and classification
Applications in aerospace
Hand lay up, spray,
Bag moulding - vacuum, pressure, auto enclave
Filament winding
Pultrusion and pulforming
Injection and blow moulding
MMC
Why they are useful? What base metals to select?
Plasma spray, Ospray
Liquid infiltration, squeeze casting
Bag Moulding
Liquid Metal infiltration
Technique
In liquid metal infiltration process, the pressure is applied through
a gas.
The pre-form is inserted into the Die.
The chamber containing the molten metal is evacuated and then a
gas is forced into the chamber to infiltrate the pre-form.
The pressure causes the molten metal to infiltrate the pre-form.
The pressure is maintained for a short duration of time for
solidification.
Bag Moulding Technique
Solid state fabrication
1. Diffusion bonding
2. Explosive welding
3. High energy rate forming
4. Powder metallurgy
Diffusion Bonding
Bag Moulding Technique
Aluminum foils (.05mm thick) are normally used for
producing MMC's.
SiC coated boron fibers (borsic fibred) are sandwiched
between two Al foils.
Acrylic binder is used to retain the fibers in its place. This is
called a ply.
A number of plies are made after trimming each ply to the
desired dimensions.
These plies are stacked in such a way that the fibers in each
ply are oriented according to the design requirements. The
number of plies will depend on the thickness of the part.
Diffusion Bonding
Bag Moulding Technique
The plies are then enclosed and evacuated to remove
oxygen.
The laminate is then heated to a temperature of 300°C
and is compacted in a die at a pressure of 35 MPa.
During heating or compaction, matrix atoms diffuse
across the matrix/fiber interface and a strong bond is
obtained.
Since diffusion bonding involves lower temperatures
for consolidation, fiber coat ing is not as critical as in
liquid state fabrication.
Diffusion Bonding
Bag strength
Since bonding Moulding Technique
between fiber and matrix
depends on the effectiveness of diffusion, it is essential
to maintain clean constituent surfaces.
While the fibers can be cleaned either by acid or
alkaline solutions, the matrix metal foils can be
cleaned by carbon tetrachloride solution.
In the case of Boron fiber reinforced metals, preforms
are made directly by combining the fiber and the metal
foil with a fugitive binder.
The fugitive binder is also known as Polymer cement
(essentially of thermo-plastic resin).
Diffusion Bonding
Bag Moulding Technique
Each preform will have fibers oriented longitudinal to
the fiber direction.
The fugitive binder evaporates during hot - Pressing
operations.
While laying up the preforms as Plies, each of the ply is
laid with fiber axis oriented a desired by the design.
In the case of SiC or Graphite or Alumina fiber as
reinforced metals, the pre- forms are made by a
Filament winding process.
Diffusion Bonding
Bag Moulding Technique
The metal fibers are wound on a Drum coated with a
fugitive binder.
Before the fibers enter the Drum they are stretched to
a pre-determined tension and aligned.
The spacing and the width of the preform can be
adjusted by a suitable mechanism.
The drum must be made of a material (preferably
made of copper based alloy) that conducts heat due to
exothermic reaction during curing process of the resin.
