Metal Matrix Composites: A Modern Approach to Manufacturing

Metal matrix composites (MMCs) are a family of strong yet lightweight materials that have many industrial uses, particularly in the automotive, aerospace, and thermal management industries. By choosing the best combinations of matrix, reinforcement, and manufacturing techniques, the structural and functional features of MMCs may be adjusted to meet the requirements of diverse industrial applications. The matrix, the interaction between them, and the reinforcement all affect how MMCs behave. Yet, there is still a significant problem in developing a large-scale, costeffective MMC production method with the necessary geometrical and operational flexibility. This chapter provides an overview of Metal Matrix Composites (MMCs), their historical development, properties of MMCs, classification of MMCs, diverse applications, and the relevance of MMCs to sustainable industries.

Metal matrix composites (MMCs) having particulate or laminate structure are extensively used in a wide range of applications including cutting tools, automotive vehicles, aircraft, and consumer electronics. In a composite material, two or more dissimilar materials are combined to form another material having superior properties. The matrix is a continuous phase in a composite material and is usually more ductile and less hard phase. In the matrix phase, aluminum, magnesium, titanium and copper are some of the metals widely used matrix materials. Compared with unreinforced metals, MMCs offer much better mechanical and thermal properties as well as the opportunity to tailor these properties for a particular application. In order to fabricate MMCs, various processing techniques have been evolved which can be categorized as liquid state method: Stir Casting, Infiltration, Gas Pressure Infiltration, Squeeze Casting Infiltration, Pressure Die Infiltration, solid state method: Diffusion bonding, Sintering and vapor state method: Electrolytic co-deposition, Spray co-deposition and Vapor co-deposition. The microstructure of MMCs such as orientation, distribution and aspect ratio of reinforced phase can effectively influence the properties of composite materials. The effective properties of MMCs can be predicted using the analytical or numerical methods. Analytical methods such as: Turner Model, Kerner Model, Schapery bonds, Hashin’s bond and Rule-of-Mixtures are used widely for effective properties computation. However, analytical methods cannot take into account the material microstructure, and therefore, the finite element method has been used extensively to model the real microstructure of composites and to predict the deformation response and effective properties of composites.

In this review article, the current status of and recent developments in fabrication techniques for all types of Silicon Carbide reinforced Aluminium Metal Matrix Composites (SiC-AMMCs) have been elaborately discussed. The comparative studies on fabrication methods have also been reported in this article. Furthermore, the possible interfacial reactions between aluminium and silicon carbide that have been presented by researchers were also explored and their causes and remedies have been discussed. The entire discussion in this review article reveals that liquid fabrication processes (especially stir casting) are used effectively for mass production, intricate shapes, a variety of products, nano-composites, etc. The solid-state processes are performed below the melting temperature of matrices, resulting in the least possible interfacial reactions leading to unwanted compounds’ formation. The literature on interfacial reactions reveals that the Al4C3 compound is mostly formed as a result of the reactions between aluminium and silicon carbide and exhibits a deleterious effect on the composite properties.

In this chapter, an overview of the advancement and research efforts that have been undertaken on CFR-MMC (carbon-fiber reinforced metal matrix-based composites) during the last several decades is presented. Carbon fiber is widely implemented in the construction sector for rehabilitation and structural repair projects. Although, studies show that carbon fiber-reinforced metal-matrix (CFR-MMC) has a bright future, the use of carbon fibre as a reinforcement in metal matrix is still in its development. The uses, and traits of carbon fiber are discussed in general terms in this study. The various traits such as mechanical, and structural properties of the resultant CFR-MMC, are significantly influenced by the structure and content of the carbon fibre as well as its bonding to the MM (Metal matrix). The effect on the various traits of MMCs by CFs (Carbon fibers) was investigated. In addition, a detailed study on the various synthesis approaches for the preparation of CFR-MMC has been taken into practice in this book chapter.

Recent advances in various engineering applications demand new materials that have multi-functionality along with suitable structural properties. Metal matrix composites are the class of materials that satisfy this purpose due to their lightweight, increased strength, and other improved mechanical properties. These composite materials can be prepared by various conventional techniques which aim reducing the cost of production and meeting the demand of the industries efficiently. The properties and functionality of these materials are greatly influenced by the type of reinforced particulates and their composition in the metal matrix. Many reinforcement particles or fibers can be used in MMC depending upon the applications. Commonly used reinforced materials are graphene, polymers, carbon fibers, ceramic materials, etc. Among the carbon family, carbon nanotubes (CNT) exhibit enhanced performance as an ideal reinforcement material for MMCs. With outstanding intrinsic physical properties, CNTs are considered a promising candidate for reinforcement. CNT owes its properties due to its small diameter, high tensile strength, stiffness, high Young’s modulus, and good chemical stability. They exhibit thermal stability even at high temperatures and exhibit good electrical conductivity. They also show improved fatigue resistance and plasticity and thus broaden the performance of the MMC. In this chapter, various fabrication techniques along with blending and processing methods of CNT-reinforced MMC have been discussed. The main methods have been explained with their schematic representations. The advantages and limitations of these methods have also been discussed. A strong interfacial bonding between the reinforced particulate and the metal matrix affects the performance of the material. This chapter also deals with a deep understanding of the various interfacial bonds that can exist between CNT and the metal matrix

Tribology deals with basic principles and understanding of three concepts: friction, wear, and lubrication. Now, bio tribology is one of the most exhilarating fields of tribological study. In this book chapter, the authors made efforts to review and provide brief thoughts about the various sections of the biotribology such as orthopedics, artificial implants, biomimetics, bio-lubricants, biomaterials, ocular tribology, skin tribology, haptics, dental tribology, sports tribology. Apart from these, biotribology deals with a few more exciting areas i.e., in personal care like skin creams, cosmetics, etc., and oral processing studies such as mouthfeel and taste perception.

This comprehensive review comes to a close with four studies, i.e., bio-friction of the biological systems, tribology of medical and surgical devices, biocompatibility issues related to biomaterials, and critical aspects of bio-tribocorrosion. A critical review of bio-friction studies for the various biological systems is presented, and significant underlying tribological-lubrication mechanisms are also discussed.

The present emphasis and forthcoming advancements of the various medical and surgical instruments in context with the fundamental tribology principles and pertaining mechanisms for an efficient, versatile, and multi-functional bio-system will be discussed in this book chapter. Furthermore, major challenges faced by R&D officials and medical teams are discussed.

Biocompatibility and bio-tribo-corrosion of biomaterials are serious concerns in bio tribology. In-depth discussions of current trends, implementations, and their guidelines for the future are also included. In a nutshell, bio tribology studies can contribute noteworthy scientific, social, engineering, and healthcare benefits; the openings and possibilities are significant.

In today’s world, there are different materials that are already used in certain applications and have been performing well. As the need and the complications in certain areas have been progressively discovered, there is a wide requirement for materials’ research that has a combined effect of more than one property which is a limitation of monolithic materials. To have such an effect, the fabrication of certain materials having a well-tailored blend of properties as per the reinforcement is used to form a composite. A review has been carried out for the various research works and the effort is being made to summarize the effect of mono and hybrid reinforcements on the materialistic properties as compared to the base material.

The need to develop and use materials that are both much lighter and stronger than current materials but are also more energy-efficient has been felt due to the ongoing depletion of resources and the rising demand for component efficiency. Composites are the best available suitable materials due to their excellent ultra-light weight and outstanding strength characteristics. They have great energy absorption capacity, high stiffness, high fracture toughness, and low thermal expansionin addition to being highly strong in effect and light in weight. Today, composites are being used in an increasing number of technical fields, from the automotive to aviation.

Metal matrix composite (MMC) has several attractive characteristics (low coefficient of thermal expansion, lightweight, better abrasion, high strength-to-weight ratio, superior stiffness, thermal stability, etc.), when compared with monolithic materials. Due to these charming characteristics, MMC materials have received wide scope in distinct industries (marine, aerospace, defence, mineral processing industry, automotive, electronic, and recreation industries, etc.). But, owing to the requirement of higher ductility and brittleness in the form of reinforcement and matrix, there is a need to improve the properties of composite (MMC) that will fulfil the requirement of the engineers. In addition, MMCs are typically more prone to corrosion and wear as compared to their monolithic matrix alloys. Thus, the study of corrosion and wear behaviour of distinct composites such as Al/SiC etc. are highly important for better corrosion resistance for distinct applications. This chapter provides an overview of the corrosion and wear behaviour of MMCs and applications.

The aim of this investigation is to investigate the contribution of controllable input parameters (viz. pulse on times, peak currents) on the performance of two newly developed MMCs (Al-8.5%SiC-1.5%Mo and Al-7%SiC-3%Mo). Both the metal matrix composites were fabricated using the stir-casting method. Thereafter, various tests such as microhardness test, tensile test, and porosity analysis of the newly developed composite were performed. To carry out the machining trials, an L18 orthogonal array (OA) was chosen. Optimization of the machining process was performed according to Taguchi analysis followed by grey relational analysis (GRA). The results showed that with increasing weight fraction of the molybdenum particulates, microhardness and density of the composites increase with a small reduction in the tensile strength. In addition, pulse on time is the most contributing parameter among others to obtain optimal process performance. The optimum setting of input variables suggested by GRA to obtain optimal responses is a molybdenum composition of 3%, Pulse on time of 70 µs, and a peak current of 9A. Based on the interaction plot, it is evident that process performance measures of EDM depend on controllable input parameters.