Copper:-

Classification of Copper alloy

• Brass (Alloy of Copper and Zinc) – 2 types
➢ Alpha Brass (Upto 36 Wt.% Zn) – 2 types
• Yellow brass (20-36Wt.% Zn)
• Red brass (5-20Wt.% Zn)
➢ Alpha plus beta brass (36 to 46% Zn)
• Brass is the most common alloy of Cu with Zn
• Brass has higher ductility than copper or zinc.
• Easy to cast - Relatively low melting point and high fluidity
• Properties can be tailored by varying Zn content.

• Brass is frequently used to make musical instruments

(good ductility and acoustic properties). 2
 Bronze
Bronze:- (Copper and Tin)

• Copper alloys containing tin, lead, aluminum, silicon and

nickel are classified as bronzes.
• Cu-Sn Bronze is one of the earliest alloy to be discovered.
• Cu ores invariably contain Sn. Stronger than brasses with
good corrosion and tensile properties; can be cast, hot
worked and cold worked.
• Wide range of applications: Ball bearings,
surgical and dental instruments.

Bronze bearing
 Aluminium alloy system

Intermetallics formed in Age hardening alloys:

MgZn2, Mg2Si, CuAl2, Mg3Zn3Al2, Al2CuMg, Mg2Al3, NiAl3, AlSiMnFe, Al6Cu3Ni,
Al12Mn2Cu etc.
4
 Major aluminium alloy system

R. Gitter et. al.,

Department of Mechanical and Manufacturing Engineering, MIT, Manipal 5
 Heat treatable Aluminium alloys
Aluminium alloys of this class belong to
• Limited solubility in solid state.
• Alloy system should be temperature-dependent equilibrium solid solubility,
which increases with rise in temperature.
• Possibility of retaining single phase super saturated solid solution by quenching
and precipitation of coherent/ partially coherent phase by decomposition of the
super saturated solid solution.

Example:-
• 2XXX series of Al-Cu alloys and Al-Cu-Mg alloys.
• 6XXX series include Al-Mg-Si alloys.
• 7XXX series include Al-Zn, Al-Zn-Mg, and Al-Zn-Mg-Cu alloys.

Cont’d…
6
 Non-Heat treatable Aluminium alloys
Cont’d…
➢ Doesn’t show decrease of solid solubility with the decrease of temperature.

➢ Consist of a homogeneous solid solution with non-coherent precipitates and

show low strength and high ductility.

➢ Further increase in strength :- cold work, such as cold rolling, cold swaging,
tube drawing etc.

➢ Example:-
• Pure aluminium (1XXX),
• Al-Mn (3XXX), Al-Mn-Mg and Al-Si alloys

7
 Al-Cu alloy
Duralumin: Al –Cu alloy with less than 5 wt% Cu and
trace additions of Mg, Zn, Ni, Si etc.

Age hardenable alloy. It is possible to improve hardness

and strength of the alloy by heat treatment. Generally
used in air craft and automobile industries.
THANK YOU
 Composite Materials

• Introduction to composite materials: Definition,

classification of composites based matrix materials &
reinforcements, manufacturing of fibrous composites,
laminated composites, particulate composites (Hand
lay-up, Filament winding, Pultrusion, Slip casting and
Stir casting), advantages and application of
composites. [06]

Mechanical Engineering Dept. 10

What is a composite Material?

Man-Made materials
Broad Definition: Two or more chemically distinct materials which when
combined have improved properties over the individual materials. OR
A combination of 2 or more materials having compositional variations and
depicting properties distinctively different from those of the individual.

Composites could be natural or synthetic.

Mechanical Engineering Dept. 11

 Example :- composite Material?
Composites could be natural or synthetic.
Wood is a good example of a natural composite, combination of cellulose fiber
and lignin. The cellulose fiber provides strength and the lignin is the "glue" that
bonds and stabilizes the fiber.

The ancient Egyptians manufactured composites! Adobe bricks are a good

example. The combination of mud and straw forms a composite that is stronger
than either the mud or the straw by itself.

Mechanical Engineering Dept. 12

Components of composite materials
Composites are combinations of two materials in which one of
the material is called the reinforcing phase, is in the form of
fibers, sheets, or particles, and is embedded in the other
material called the matrix phase.

Matrix materials Reinforcement: fibers

Polymers Glass
Metals Carbon
Ceramics Boron
Ceramic
Metallic

Mechanical Engineering Dept. 13

 Classification of Composite materials
Based on type of matrix :
Composites – Polymer Matrix

Mechanical Engineering Dept. 18

Glass fiber

Mechanical Engineering Dept. 19

Composites – Ceramic Matrix
A Ceramic Matrix Composite (CMC) is a ceramic matrix coupled with embedded ceramic fibers. This unique
association of materials revolutionized the aerospace industry, making parts more resistant to extreme
conditions and lighter compared to the previous technologies.

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 1650oC.
Fiber materials used commonly are carbon and aluminum oxide.

Mechanical Engineering Dept. 21

 Classification of Composite materials
Based on type of Reinforcement :
Manufacturing Methods / Processing of Polymer Matrix Compoistes :
 Typical Applications:
Hand Lay-up method :
Wind-turbine blades, production boats, architectural
Description mouldings.
Fibers are in the form of woven, knitted, stitched or bonded fabrics.
Resins are impregnated by hand into fibers.

This is usually accomplished by rollers or brushes, with an increasing use of nip-

roller type impregnators for forcing resin into the fabrics by means of rotating rollers
and a bath of resin.
Laminates are left to cure under standard atmospheric conditions.
 Main Advantages:
• Simple principle.
• Low cost tooling, if room-temperature cure resins are used.
• Wide choice of suppliers and material types.
• Higher fiber contents may be used.
Disadvantages:
• Resin mixing, laminate resin contents, and laminate quality are very dependent
on the skills of laminators. Low resin content laminates cannot usually be
achieved without the incorporation of excessive quantities of voids.

• Health and safety considerations of resins. The lower molecular weights of hand
lay-up resins are harmful than higher molecular weight products.
• Difficult to process if the viscosity of the resins is higher.
Manufacturing Methods of PMC’s :
Filament Winding method :

• This process is primarily used for hollow, generally circular or oval sectioned
components, such as pipes and tanks.
• Fiber tows are passed through a resin bath before being wound onto a mandrel in a
variety of orientations, controlled by the fiber feeding mechanism, and rate of
rotation of the mandrel.
Manufacturing Methods of PMC’s :
Filament Winding method :

Main Advantages:
i) This can be a very fast and therefore economic method.
ii) Resin content can be controlled by metering the resin onto each fiber tow through
nips or dies.
iii) Structural properties of laminates can be very good since straight fibers can be
laid in a complex pattern to match the applied loads.
Main Disadvantages:
i) The process is limited to convex shaped components.
ii) Fiber cannot easily be laid exactly along the length of a component- Skill.
iii) Mandrel costs for large components can be high.
Manufacturing Methods of PMC’s :Typical Applications:
Pultrusion method : Beams and girders used in roof structures
bridges, ladders, frameworks.
 Manufacturing Methods of PMC’s :
Pultrusion method :

• Fibers are pulled from a creel through a resin bath and then through a heated die.
• The die completes the impregnation of the fiber, controls the resin content
and cures the material into its final shape as it passes through the die.
• This cured profile is then automatically cut to length.
Manufacturing Methods of PMC’s :
Pultrusion method :
Main Advantages:
i) This can be a very fast, economic way of impregnating and curing materials.
ii) Resin content can be accurately controlled.
iii) Fiber cost is minimised since the majority is taken from a creel.
iv) Structural properties of laminates can be very good since the profiles have very
straight fibers and high fiber volume fractions can be obtained.
v) Resin impregnation area can be enclosed thus limiting volatile emissions.

Main Disadvantages:
i) Limited to constant or near constant cross-section components- symmetrical
ii) Heated die costs can be high.

Typical Applications:
Beams and girders used in roof structures, bridges, ladders,
frameworks.
Metal Matrix Composites
(MMC):
Metal Matrix Composite (MMC) is a material consisting of a metallic
matrix combined with metallic (lead, tungsten, molybdenum) or a ceramic
(oxides, carbides) dispersed phase.
Properties of MMC’s:
• High strength, fracture toughness and stiffness.
• They can withstand elevated temperature in corrosive environment.
• Most metals and alloys could be used as matrices.
• The reinforcement are stable over a range of temperature and non-reactive too.
• Light metals form the matrix and the reinforcements are of high moduli.
Main types of MMC:
• Aluminum Matrix Composites (AMC)
• Magnesium Matrix Composites
• Titanium Matrix Composites
• Copper Matrix Composites
 Metal Matrix Composites (MMC):
Aluminum Matrix Composites (AMC)

• This is the widest group of Metal

Matrix Composites.
• Matrices of Aluminum Matrix
Composites are usually based on
aluminum-silicon (Al-Si) alloys.

• Aluminum Matrix Composites (AMC) are reinforced by: Alumina (Al2O3) or

silicon carbide (SiC) particles (particulate Composites) in amounts 15-70 vol%.
• Continuous fibers of alumina, silicon carbide, Graphite (long-fiber reinforced
composites).
• Discontinuous fibers of alumina (short-fiber reinforced composites).
❖ Aluminum Matrix Composites (AMC) are used for manufacturing automotive
parts (pistons, pushrods, brake components), brake rotors for high speed
trains, bicycles, golf clubs, and electronic substrates.
Metal Matrix Composites (MMC):
Magnesium Matrix Composites
• Magnesium Matrix Composites are reinforced mainly by silicon carbide (SiC) particles
(particulate composites)
The following properties are typical for Magnesium Matrix Composites:
• Low density;
• High stiffness (modulus of elasticity);
• High wear resistance;
• Good strength even at elevated temperatures;
• Good creep resistance.

❖ Magnesium Matrix Composites are used for

manufacturing components for racing cars,
lightweight automotive brake system, aircraft
parts, gearboxes, transmissions, compressors and
engine.
Metal Matrix Composites (MMC):
Titanium Matrix Composites: -powder metallurgy method.

• Are reinforced mainly by continuous

monofilament silicon carbide fiber
• Titanium boride (TiB2) and titanium
carbide (TiC) particles (particulate
composites).

The following properties are typical for Titanium Matrix Composites:

• High strength and high stiffness (modulus of elasticity);
• High creep resistance;
• High thermal stability;
• High wear resistance.
Titanium Matrix Composites are used for manufacturing structural components of the F-16
jet’s landing gear, turbine engine components, automotive engine components, drive train
parts, general machine components.
Metal Matrix Composites (MMC):

Copper Matrix Composites

• Are reinforced by continuous fibers of
carbon, silicon carbon (SiC), tungsten
(W), and stainless steel;
• Particulate composites (SiC particles).

Powder metallurgy (sintering) and infiltration technique are used for fabrication
Copper Matrix Composites.
The following properties are typical for Copper Matrix Composites:
• Low coefficient of thermal expansion
• High stiffness (modulus of elasticity)
• Good electrical conductivity
• High thermal conductivity.
Metal Matrix Composites (MMC):
Fabrication Methods:
Liquid state fabrication of Metal Matrix Composites
▪ Liquid state fabrication of Metal Matrix Composites involves incorporation
of dispersed phase into a molten matrix metal, followed by its solidification.
▪ In order to provide high level of mechanical properties of the composite, good
interfacial bonding (wetting) between the dispersed phase and the liquid matrix
should be obtained.
The methods of liquid state fabrication of Metal Matrix Composites:

➢Stir Casting
Metal Matrix Composites (MMC):
Fabrication Methods:
Stir Casting:

Stir Casting is a liquid state method of

composite materials fabrication, in
which a dispersed phase (ceramic
particles, short fibers) is mixed with a
molten matrix metal by means of
mechanical stirring.
This approach involves
mechanical mixing of the reinforcement particulates/particles into a molten metal bath.
• A crucible is heated to melt aluminum metal, with a motor and blades is placed in the
crucible that helps to get uniform molten metal.
• The reinforcement is poured into the crucible above the melt surface and at a controlled
rate, to ensure a smooth and continuous feed.
• As the blades rotate at moderate speeds, it generates a uniform mixing of the
reinforcement particles into the melts to produce homogenous composites
Metal Matrix Composites (MMC):
Fabrication Methods:
Stir Casting is characterized by the following features:
• Content of dispersed phase is limited (usually not more than 30 vol.%).
• Distribution of dispersed phase throughout the matrix is not perfectly
homogeneous:
• There are local clouds (clusters) of the dispersed particles (fibers);
• There may be gravity segregation of the dispersed phase due to a difference in
the densities of the dispersed and matrix phase.
• The technology is relatively simple and low cost.
Thank You